Synthesis of metal complexes and uses thereof

ABSTRACT

The present disclosure provides novel methods of making aluminum complexes with utility for promoting epoxide carbonylation reactions. Methods include reacting neutral metal carbonyl compounds with alkylaluminum complexes.

CROSS REFERENCE TO RELATED APPLICATIONS

The present invention claims priority to U.S. provisional patentapplication No. 62/028,993, filed Jul. 25, 2014, the entire contents ofwhich are hereby incorporated by reference.

ACKNOWLEDGMENT OF GOVERNMENT SUPPORT

This invention was made with Government support under Grant No.DE-EE0005766, awarded by the Department of Energy. The government hascertain rights in the invention.

BACKGROUND OF THE INVENTION

Bimetallic complexes containing a cationic metal-centered Lewis acid incombination with an anionic metal carbonyl are highly active catalystsfor the ring-expanding carbonylation of strained heterocycles, includingepoxides, aziridines, oxetanes and lactones. In particular, suchbimetallic catalysts comprising a cationic aluminum complex as aLewis-acidic component and a carbonyl cobaltate anion are useful for thedouble carbonylation of epoxides to succinic anhydrides (Rowley et al.,J. Am. Chem. Soc., 2007, 129, 4948-4960).

The syntheses of such aluminum carbonyl cobaltate complexes reported todate in the literature rely on a salt metathesis reaction performed bytreating a chloroaluminum complex with a cobalt tetracarbonyl alkalimetal salt to produce the desired aluminum cobaltate catalyst along withalkali metal chloride. Unfortunately, this procedure has features thatmake its implementation on large scale impractical. Firstly, the alkalimetal salt of the carbonyl cobaltate utilized for the synthesis is notcommercially available and must be formed in a separate step (typicallyfrom dicobalt octacarbonyl) then isolated and purified prior to use. Inaddition, the final catalyst product must be purified to remove residualalkali metal salts. Typically, this is done by recrystallizing the airsensitive catalyst which, while practicable at laboratory scale, isproblematic at production volumes. As such, there remains a need formethods of making aluminum carbonyl cobaltate complexes that arepractical and efficient for large-scale use.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides methods of synthesizingionic aluminum-based carbonylation catalysts.

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound, where each of Q, R^(q), M, Q′,d, e, w, and y is as defined below and in the classes and subclassesherein.

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I′:

with a neutral metal carbonyl compound, where each of Q, R^(q′), M, Q′,d, e, w, and y is as defined below and in the classes and subclassesherein.

In another aspect, the present invention provides methods ofsynthesizing neutral aluminum-based carbonylation catalysts.

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

-   -   where each of Q, M, Q′, R^(q), R^(a′), R^(b′), R^(c′), R^(d′),        w, and d are as defined above and in the classes and subclasses        herein.

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I′:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

-   -   where each of Q, M, Q′, R^(q), R^(a′), R^(b′), R^(c′), R^(d′),        w, and d are as defined above and in the classes and subclasses        herein,

In another aspect, the present invention encompasses methods forproviding carbonylation catalysts to an epoxide carbonylation reaction.In certain embodiments of such methods, the epoxide carbonylationreaction comprises a reaction zone where an epoxide (or mixture of twoor more epoxides) is contacted with carbon monoxide. In certainembodiments, such methods entail feeding the reaction zone withcarbonylation catalyst by providing two separate catalyst feed streams:a first catalyst feed stream containing a compound of formula I or I′(as defined above and in the classes and subclasses herein) and a secondcatalyst feed stream containing a neutral metal carbonyl compound (asdefined above and in the classes and subclasses herein).

In another aspect, the present invention encompasses methods for thesynthesis of symmetrical ketones.

In certain embodiments, such methods comprise the step of contacting analuminum compound of formula I:

with a neutral metal carbonyl compound (as defined below and in theclasses and subclasses herein) to provide a product having a formula:

where each of Q and R^(q) are as defined below and in the classes andsubclasses herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a representative process schematic of a disclosedcontinuous carbonylation method where a first catalyst feed stream andsecond catalyst feed stream are fed directly to a continuouscarbonylation reactor.

FIG. 2 shows an alternate process schematic of a disclosed continuouscarbonylation method where a first catalyst feed stream and secondcatalyst feed stream are combined in a mixer prior to being fed to acontinuous carbonylation reactor.

DEFINITIONS

Definitions of specific functional groups and chemical terms aredescribed in more detail below. For purposes of this invention, thechemical elements are identified in accordance with the Periodic Tableof the Elements, CAS version, Handbook of Chemistry and Physics,75^(th)Ed., inside cover, and specific functional groups are generallydefined as described therein. Additionally, general principles oforganic chemistry, as well as specific functional moieties andreactivity, are described in Organic Chemistry, Thomas Sorrell,University Science Books, Sausalito, 1999; Smith and March March'sAdvanced Organic Chemistry, 5^(th) Edition, John Wiley & Sons, Inc., NewYork, 2001; Larock, Comprehensive Organic Transformations, VCHPublishers, Inc., New York, 1989; Carruthers, Some Modern Methods ofOrganic Synthesis, 3^(rd) Edition, Cambridge University Press,Cambridge, 1987; the entire contents of each of which are incorporatedherein by reference.

The terms “halo” and “halogen” as used herein refer to an atom selectedfrom fluorine (fluoro, —F), chlorine (chloro, —Cl), bromine (bromo,—Br), and iodine (iodo, —I).

The term “aliphatic” or “aliphatic group”, as used herein, denotes ahydrocarbon moiety that may be straight-chain (i.e., unbranched),branched, or cyclic (including fused, bridging, and spiro-fusedpolycyclic) and may be completely saturated or may contain one or moreunits of unsaturation, but which is not aromatic. Unless otherwisespecified, aliphatic groups contain 1-30 carbon atoms. In certainembodiments, aliphatic groups contain 1-12 carbon atoms. In certainembodiments, aliphatic groups contain 1-8 carbon atoms. In certainembodiments, aliphatic groups contain 1-6 carbon atoms. In someembodiments, aliphatic groups contain 1-5 carbon atoms, in someembodiments, aliphatic groups contain 1-4 carbon atoms, in yet otherembodiments aliphatic groups contain 1-3 carbon atoms, and in yet otherembodiments aliphatic groups contain 1-2 carbon atoms. Suitablealiphatic groups include, but are not limited to, linear or branched,alkyl, alkenyl, and alkynyl groups, and hybrids thereof such as(cycloalkyl)alkyl, (cycloalkenyl)alkyl, or (cycloalkyl)alkenyl.

The term “heteroaliphatic” or “heteroaliphatic group”, as used herein,denotes an optionally substituted hydrocarbon moiety having, in additionto carbon atoms, from one to five heteroatoms, that may bestraight-chain (i.e., unbranched), branched, or cyclic (“heterocyclic”)and may be completely saturated or may contain one or more units ofunsaturation, but which is not aromatic. The term “heteroatom” refers tonitrogen, oxygen, or sulfur, and includes any oxidized form of nitrogenor sulfur, and any quaternized form of a basic nitrogen. The term“nitrogen” also includes a substituted nitrogen. Unless otherwisespecified, heteroaliphatic groups contain 1-6 carbon atoms wherein 1-3carbon atoms are optionally and independently replaced with heteroatomsselected from oxygen, nitrogen, and sulfur. In some embodiments,heteroaliphatic groups contain 1-4 carbon atoms, wherein 1-2 carbonatoms are optionally and independently replaced with heteroatomsselected from oxygen, nitrogen, and sulfur. In yet other embodiments,heteroaliphatic groups contain 1-3 carbon atoms, wherein 1 carbon atomis optionally and independently replaced with a heteroatom selected fromoxygen, nitrogen, and sulfur. Suitable heteroaliphatic groups include,but are not limited to, linear or branched, heteroalkyl, heteroalkenyl,and heteroalkynyl groups.

The term “epoxide”, as used herein, refers to a substituted oxirane.Such substituted oxiranes include monosubstituted oxiranes,disubstituted oxiranes, trisubstituted oxiranes, and tetrasubstitutedoxiranes. Such epoxides may be further optionally substituted as definedherein. In certain embodiments, epoxides comprise a single oxiranemoiety. In certain embodiments, epoxides comprise two or more oxiranemoieties.

The term “unsaturated”, as used herein, means that a moiety has one ormore double or triple bonds.

The terms “cycloaliphatic”, “carbocycle”, or “carbocyclic”, used aloneor as part of a larger moiety, refer to a saturated or partiallyunsaturated monocyclic, bicyclic, or polycyclic ring systems, asdescribed herein, having from 3 to 20 members, wherein the aliphaticring system is optionally substituted as defined above and describedherein. Cycloaliphatic groups include, without limitation, cyclopropyl,cyclobutyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl,cycloheptyl, cycloheptenyl, cyclooctyl, cyclooctenyl,bicyclo[2.2.1]heptyl, norbornyl, spiro[4.5]decyl, and cyclooctadienyl.In some embodiments, a cycloaliphatic group has 3-6 carbons. The terms“cycloaliphatic”, “carbocycle”, or “carbocyclic” also include aliphaticrings that are fused to one or more aromatic or nonaromatic rings, suchas decahydronaphthyl or tetrahydronaphthyl, where the radical or pointof attachment is on the aliphatic ring. In some embodiments, acarbocyclic group is bicyclic. In some embodiments, a carbocyclic groupis tricyclic. In some embodiments, a carbocyclic group is polycyclic. Incertain embodiments, the term “C₃-C₁₄ carbocycle” refer to a 3- to8-membered saturated or partially unsaturated monocyclic carbocyclicring, or a 7- to 14-membered saturated or partially unsaturatedpolycyclic carbocyclic ring.

The term “alkyl,” as used herein, refers to saturated, straight- orbranched-chain hydrocarbon radicals derived from an aliphatic moietycontaining between one and six carbon atoms by removal of a singlehydrogen atom. Unless otherwise specified, alkyl groups contain 1-12carbon atoms. In certain embodiments, alkyl groups contain 1-8 carbonatoms. In certain embodiments, alkyl groups contain 1-6 carbon atoms. Insome embodiments, alkyl groups contain 1-5 carbon atoms. In someembodiments, alkyl groups contain 1-4 carbon atoms. In certainembodiments, alkyl groups contain 1-3 carbon atoms. In some embodiments,alkyl groups contain 1-2 carbon atoms. Examples of alkyl radicalsinclude, but are not limited to, methyl, ethyl, n-propyl, isopropyl,n-butyl, iso-butyl, sec-butyl, sec-pentyl, iso-pentyl, tert-butyl,n-pentyl, neopentyl, n-hexyl, sec-hexyl, n-heptyl, n-octyl, n-decyl,n-undecyl, dodecyl, and the like.

The term “alkenyl,” as used herein, denotes a monovalent group derivedfrom a straight- or branched-chain aliphatic moiety having at least onecarbon-carbon double bond by the removal of a single hydrogen atom.Unless otherwise specified, alkenyl groups contain 2-12 carbon atoms. Incertain embodiments, alkenyl groups contain 2-8 carbon atoms. In certainembodiments, alkenyl groups contain 2-6 carbon atoms. In someembodiments, alkenyl groups contain 2-5 carbon atoms. In someembodiments, alkenyl groups contain 2-4 carbon atoms. In someembodiments, alkenyl groups contain 2-3 carbon atoms. In someembodiments, alkenyl groups contain 2 carbon atoms. Alkenyl groupsinclude, for example, ethenyl, propenyl, butenyl, 1-methyl-2-buten-1-yl,and the like.

The term “alkynyl,” as used herein, refers to a monovalent group derivedfrom a straight- or branched-chain aliphatic moiety having at least onecarbon-carbon triple bond by the removal of a single hydrogen atom.Unless otherwise specified, alkynyl groups contain 2-12 carbon atoms. Incertain embodiments, alkynyl groups contain 2-8 carbon atoms. In certainembodiments, alkynyl groups contain 2-6 carbon atoms. In someembodiments, alkynyl groups contain 2-5 carbon atoms, in someembodiments, alkynyl groups contain 2-4 carbon atoms, in yet otherembodiments alkynyl groups contain 2-3 carbon atoms, and in yet otherembodiments alkynyl groups contain 2 carbon atoms. Representativealkynyl groups include, but are not limited to, ethynyl, 2-propynyl(propargyl), 1-propynyl, and the like.

The term “aryl” used alone or as part of a larger moiety as in“aralkyl”, “aralkoxy”, or “aryloxyalkyl”, refers to monocyclic andpolycyclic ring systems having a total of five to 20 ring members,wherein at least one ring in the system is aromatic and wherein eachring in the system contains three to twelve ring members. The term“aryl” may be used interchangeably with the term “aryl ring”. In certainembodiments of the present invention, “aryl” refers to an aromatic ringsystem which includes, but is not limited to, phenyl, biphenyl,naphthyl, anthracyl and the like, which may bear one or moresubstituents. Also included within the scope of the term “aryl”, as itis used herein, is a group in which an aromatic ring is fused to one ormore additional rings, such as benzofuranyl, indanyl, phthalimidyl,naphthimidyl, phenantriidinyl, or tetrahydronaphthyl, and the like. Incertain embodiments, the terms “6- to 10-membered aryl” and “C₆-C₁₀aryl” refer to a phenyl or an 8- to 10-membered polycyclic aryl ring.

The terms “heteroaryl” and “heteroar-”, used alone or as part of alarger moiety, e.g., “heteroaralkyl”, or “heteroaralkoxy”, refer togroups having 5 to 14 ring atoms, preferably 5, 6, or 9 ring atoms;having 6, 10, or 14 π electrons shared in a cyclic array; and having, inaddition to carbon atoms, from one to five heteroatoms. The term“heteroatom” refers to nitrogen, oxygen, or sulfur, and includes anyoxidized form of nitrogen or sulfur, and any quaternized form of a basicnitrogen. Heteroaryl groups include, without limitation, thienyl,furanyl, pyrrolyl, imidazolyl, pyrazolyl, triazolyl, tetrazolyl,oxazolyl, isoxazolyl, oxadiazolyl, thiazolyl, isothiazolyl,thiadiazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl, indolizinyl,purinyl, naphthyridinyl, benzofuranyl and pteridinyl. The terms“heteroaryl” and “heteroar-”, as used herein, also include groups inwhich a heteroaromatic ring is fused to one or more aryl,cycloaliphatic, or heterocyclyl rings, where the radical or point ofattachment is on the heteroaromatic ring. Nonlimiting examples includeindolyl, isoindolyl, benzothienyl, benzofuranyl, dibenzofuranyl,indazolyl, benzimidazolyl, benzthiazolyl, quinolyl, isoquinolyl,cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, 4H-quinolizinyl,carbazolyl, acridinyl, phenazinyl, phenothiazinyl, phenoxazinyl,tetrahydroquinolinyl, tetrahydroisoquinolinyl, andpyrido[2,3-b]-1,4-oxazin-3(4H)-one. A heteroaryl group may be mono- orbicyclic. The term “heteroaryl” may be used interchangeably with theterms “heteroaryl ring”, “heteroaryl group”, or “heteroaromatic”, any ofwhich terms include rings that are optionally substituted. The term“heteroaralkyl” refers to an alkyl group substituted by a heteroaryl,wherein the alkyl and heteroaryl portions independently are optionallysubstituted. The term “heteroaralkyl” refers to an alkyl groupsubstituted by a heteroaryl, wherein the alkyl and heteroaryl portionsindependently are optionally substituted. In certain embodiments, theterms “5- to 10-membered heteroaryl” and “C₅-C₁₀ heteroaryl” refer to a5- to 6-membered heteroaryl ring having 1 to 3 heteroatoms independentlyselected from nitrogen, oxygen, or sulfur, or an 8- to 10-memberedbicyclic heteroaryl ring having 1 to 4 heteroatoms independentlyselected from nitrogen, oxygen, or sulfur.

As used herein, the terms “heterocyclyl,” “heterocyclic radical,” and“heterocyclic ring” are used interchangeably and refer to a stable 3- to7-membered monocyclic or 7-14-membered bicyclic heterocyclic moiety thatis either saturated or partially unsaturated, and having, in addition tocarbon atoms, one or more, preferably one to four, heteroatoms, asdefined above. When used in reference to a ring atom of a heterocycle,the term “nitrogen” includes a substituted nitrogen. As an example, in asaturated or partially unsaturated ring having 0-3 heteroatoms selectedfrom oxygen, sulfur, or nitrogen, the nitrogen may be N (as in3,4-dihydro-2H-pyrrolyl), NH (as in pyrrolidinyl), or +NR (as inN-substituted pyrrolidinyl). In some embodiments, the term “C₃-C₁₄heterocycle” refers to a 3- to 8-membered saturated or partiallyunsaturated monocyclic heterocyclic ring having 1 to 2 heteroatomsindependently selected from nitrogen, oxygen, or sulfur, or a 7- to14-membered saturated or partially unsaturated polycyclic heterocyclicring having 1-3 heteroatoms independently selected from nitrogen,oxygen, or sulfur.

A heterocyclic ring can be attached to its pendant group at anyheteroatom or carbon atom that results in a stable structure and any ofthe ring atoms can be optionally substituted. Examples of such saturatedor partially unsaturated heterocyclic radicals include, withoutlimitation, tetrahydrofuranyl, tetrahydrothienyl, pyrrolidinyl,pyrrolidonyl, piperidinyl, pyrrolinyl, tetrahydroquinolinyl,tetrahydroisoquinolinyl, decahydroquinolinyl, oxazolidinyl, piperazinyl,dioxanyl, dioxolanyl, diazepinyl, oxazepinyl, thiazepinyl, morpholinyl,and quinuclidinyl. The terms “heterocyclyl,” “heterocyclyl ring,”“heterocyclic group,” “heterocyclic moiety,” and “heterocyclic radical,”are used interchangeably herein, and also include groups in which aheterocyclyl ring is fused to one or more aryl, heteroaryl, orcycloaliphatic rings, such as indolinyl, 3H-indolyl, chromanyl,phenanthridinyl, or tetrahydroquinolinyl, where the radical or point ofattachment is on the heterocyclyl ring. A heterocyclyl group may bemono- or bicyclic. The term “heterocyclylalkyl” refers to an alkyl groupsubstituted by a heterocyclyl, wherein the alkyl and heterocyclylportions independently are optionally substituted.

As used herein, the term “partially unsaturated” refers to a ring moietythat includes at least one double or triple bond. The term “partiallyunsaturated” is intended to encompass rings having multiple sites ofunsaturation, but is not intended to include aryl or heteroarylmoieties, as herein defined.

As described herein, compounds of the invention may contain “optionallysubstituted” moieties. In general, the term “substituted”, whetherpreceded by the term “optionally” or not, means that one or morehydrogens of the designated moiety are replaced with a suitablesubstituent. Unless otherwise indicated, an “optionally substituted”group may have a suitable substituent at each substitutable position ofthe group, and when more than one position in any given structure may besubstituted with more than one substituent selected from a specifiedgroup, the substituent may be either the same or different at everyposition. Combinations of substituents envisioned by this invention arepreferably those that result in the formation of stable or chemicallyfeasible compounds. The term “stable”, as used herein, refers tocompounds that are not substantially altered when subjected toconditions to allow for their production, detection, and, in certainembodiments, their recovery, purification, and use for one or more ofthe purposes disclosed herein.

In some chemical structures herein, substituents are shown attached to abond which crosses a bond in a ring of the depicted molecule. It will beappreciated that this indicates that one or more of the substituents maybe attached to the ring at any available position (usually in place of ahydrogen atom of the parent structure). In cases where an atom of a ringso substituted has two substitutable positions, two groups may bepresent on the same ring atom. Unless otherwise indicated, when morethan one substituent is present, each is defined independently of theothers, and each may have a different structure. In cases where thesubstituent shown crossing a bond of the ring is, e.g., “—R”, this hasthe same meaning as if the ring were said to be “optionally substituted”as described in the preceding paragraph.

Suitable monovalent substituents on a substitutable carbon atom of an“optionally substituted” group are independently halogen;—(CH₂)₀₋₄R^(∘); —(CH₂)₀₋₄OR^(∘); —O—(CH₂)₀₋₄C(O)OR^(∘);—(CH₂)₀₋₄CH(OR^(∘))₂; —(CH₂)₀₋₄SR^(∘); —(CH₂)₀₋₄Ph, which may besubstituted with R^(∘); —(CH₂)₀₋₄O(CH₂)₀₋₁Ph which may be substitutedwith R^(∘); —CH═CHPh, which may be substituted with R^(∘); —NO₂; —CN;—N₃; —(CH₂)₀₋₄N(R^(∘))₂; —(CH₂)₀₋₄N⁺(R^(∘))₃,—(CH₂)₀₋₄N(R^(∘))C(O)R^(∘); —N(R^(∘))C(S)R^(∘);—(CH₂)₀₋₄N(R^(∘))C(O)NR^(∘) ₂; —N(R^(∘))C(S)NR^(∘) ₂;—(CH₂)₀₋₄N(R^(∘))C(O)OR^(∘); —N(R^(∘))N(R^(∘))C(O)R^(∘);—N(R^(∘))N(R^(∘))C(O)NR^(∘) ₂; —N(R^(∘))N(R^(∘))C(O)OR^(∘);—(CH₂)₀₋₄C(O)R^(∘); —C(S)R^(∘); —(CH₂)₀₋₄C(O)OR^(∘);—(CH₂)₀₋₄C(O)N(R^(∘))₂; —(CH₂)₀₋₄C(O)SR^(∘); —(CH₂)₀₋₄C(O)OSiR^(∘) ₃;—(CH₂)₀₋₄OC(O)R^(∘); —OC(O)(CH₂)₀₋₄SR^(∘); —SC(S)SR^(∘);—(CH₂)₀₋₄SC(O)R^(∘); —(CH₂)₀₋₄C(O)NR^(∘) ₂; —C(S)NR^(∘) ₂; —C(S)SR^(∘);—SC(S)SR^(∘), —(CH₂)₀₋₄OC(O)NR^(∘) ₂; —C(O)N(OR^(∘))R^(∘);—C(O)C(O)R^(∘); —C(O)CH₂C(O)R^(∘); —C(NOR^(∘))R^(∘); —(CH₂)₀₋₄SSR^(∘);—(CH₂)₀₋₄S(O)₂R^(∘); —(CH₂)₀₋₄S(O)₂OR^(∘); —(CH₂)₀₋₄OS(O)₂R^(∘);—S(O)₂NR^(∘) ₂; —(CH₂)₀₋₄S(O)R^(∘); —N(R^(∘))S(O)₂NR^(∘) ₂;—N(R^(∘))S(O)₂R^(∘); —N(OR^(∘))R^(∘); —C(NH)NR^(∘) ₂; —P(O)₂R^(∘);—P(O)R^(∘) ₂; —OP(O)R^(∘) ₂; —OP(O)(OR^(∘))₂; SiR^(∘) ₃; —(C₁₋₄ straightor branched alkylene)O—N(R^(∘))₂; or —(C₁₋₄ straight or branchedalkylene)C(O)O—N(R^(∘))₂, wherein each R^(∘) may be substituted asdefined below and is independently hydrogen, C₁₋₈ aliphatic, —CH₂Ph,—O(CH₂)₀₋₁Ph, or a 5-6-membered saturated, partially unsaturated, oraryl ring having 0-4 heteroatoms independently selected from nitrogen,oxygen, or sulfur, or, notwithstanding the definition above, twoindependent occurrences of R^(∘), taken together with their interveningatom(s), form a 3-12-membered saturated, partially unsaturated, or arylmono- or polycyclic ring having 0-4 heteroatoms independently selectedfrom nitrogen, oxygen, or sulfur, which may be substituted as definedbelow.

Suitable monovalent substituents on R^(∘) (or the ring formed by takingtwo independent occurrences of R^(∘) together with their interveningatoms), are independently halogen, —(CH₂)₀₋₂R^(•), -(haloR^(•)),—(CH₂)₀₋₂OH, —(CH₂)₀₋₂OR^(•), —(CH₂)₀₋₂CH(OR^(•))₂; —O(haloR^(•)), —CN,—N₃, —(CH₂)₀₋₂C(O)R^(•), —(CH₂)₀₋₂C(O)OH, —(CH₂)₀₋₂C(O)OR^(•),—(CH₂)₀₋₄C(O)N(R^(∘))₂; —(CH₂)₀₋₂SR^(•), —(CH₂)₀₋₂SH, —(CH₂)₀₋₂NH₂,—(CH₂)₀₋₂NHR^(•), —(CH₂)₀₋₂NR^(•) ₂, —NO₂, —SiR^(•) ₃, —OSiR^(•) ₃,—C(O)SR^(•), —(C₁₋₄ straight or branched alkylene)C(O)OR^(•), or—SSR^(•) wherein each R^(•) is unsubstituted or where preceded by “halo”is substituted only with one or more halogens, and is independentlyselected from C₁₋₄ aliphatic, —CH₂Ph, —O(CH₂)₀₋₁Ph, or a 5-6-memberedsaturated, partially unsaturated, or aryl ring having 0-4 heteroatomsindependently selected from nitrogen, oxygen, or sulfur. Suitabledivalent substituents on a saturated carbon atom of R^(∘) include ═O and═S.

Suitable divalent substituents on a saturated carbon atom of an“optionally substituted” group include the following: ═O, ═S, ═NNR*₂,═NNHC(O)R*, ═NNHC(O)OR*, ═NNHS(O)₂R*, ═NR*, ═NOR*, —O(C(R*₂))₂₋₃O—, or—S(C(R*₂))₂₋₃S—, wherein each independent occurrence of R* is selectedfrom hydrogen, C₁₋₆ aliphatic which may be substituted as defined below,or an unsubstituted 5-6-membered saturated, partially unsaturated, oraryl ring having 0-4 heteroatoms independently selected from nitrogen,oxygen, or sulfur. Suitable divalent substituents that are bound tovicinal substitutable carbons of an “optionally substituted” groupinclude: —O(CR*₂)₂₋₃O—, wherein each independent occurrence of R* isselected from hydrogen, C₁₋₆ aliphatic which may be substituted asdefined below, or an unsubstituted 5-6-membered saturated, partiallyunsaturated, or aryl ring having 0-4 heteroatoms independently selectedfrom nitrogen, oxygen, or sulfur.

Suitable substituents on the aliphatic group of R* include halogen,—R^(•), -(haloR^(•)), —OH, —OR^(•), —O(haloR^(•)), —CN, —C(O)OH,—C(O)OR^(•), —NH₂, —NHR^(•), —NR^(•) ₂, or —NO₂, wherein each R^(•) isunsubstituted or where preceded by “halo” is substituted only with oneor more halogens, and is independently C₁₋₄ aliphatic, —CH₂Ph,—O(CH₂)₀₋₁Ph, or a 5- to 6-membered saturated, partially unsaturated, oraryl ring having 0-4 heteroatoms independently selected from nitrogen,oxygen, or sulfur.

Suitable substituents on a substitutable nitrogen of an “optionallysubstituted” group include —R^(†), —NR^(†) ₂, —C(O)R^(†), —C(O)OR^(†),—C(O)C(O)R^(†), —C(O)CH₂C(O)R^(†), —S(O)₂R^(†), —S(O)₂NR^(†) ₂,—C(S)NR^(†) ₂, —C(NH)NR^(†) ₂, or —N(R^(†))S(O)₂R^(†); wherein eachR^(†) is independently hydrogen, C₁₋₆ aliphatic which may be substitutedas defined below, unsubstituted —OPh, or an unsubstituted 5-6-memberedsaturated, partially unsaturated, or aryl ring having 0-4 heteroatomsindependently selected from nitrogen, oxygen, or sulfur, or,notwithstanding the definition above, two independent occurrences ofR^(†), taken together with their intervening atom(s) form anunsubstituted 3-12-membered saturated, partially unsaturated, or arylmono- or bicyclic ring having 0-4 heteroatoms independently selectedfrom nitrogen, oxygen, or sulfur. A substitutable nitrogen may besubstituted with three R^(†) substituents to provide a charged ammoniummoiety —N⁺(R^(†))₃, wherein the ammonium moiety is further complexedwith a suitable counterion.

Suitable substituents on the aliphatic group of R^(†) are independentlyhalogen, —R^(•), -(haloR^(•)), —OH, —OR^(•), —O(haloR^(•)), —CN,—C(O)OH, —C(O)OR^(•), —NH₂, —NHR^(•), —NR^(•) ₂, or —NO₂, wherein eachR^(•) is unsubstituted or where preceded by “halo” is substituted onlywith one or more halogens, and is independently C₁₋₄ aliphatic, —CH₂Ph,—O(CH₂)₀₋₁Ph, or a 5-6-membered saturated, partially unsaturated, oraryl ring having 0-4 heteroatoms independently selected from nitrogen,oxygen, or sulfur.

As used herein, the term “catalyst” refers to a substance the presenceof which increases the rate and/or extent of a chemical reaction, whilenot being consumed or undergoing a permanent chemical change itself.

Detailed Description of Certain Embodiments I. Methods of Making IonicAluminum-Based Carbonylation Catalysts

In one aspect, the present invention provides methods of synthesizingionic aluminum-based carbonylation catalysts.

I(a) Methods Based on Aluminum Alkyls and Aryls

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound, where

-   -   Q is independently at each occurrence a nitrogen or oxygen atom        which is part of a ligand complexed to the aluminum atom, where        any two or more Q groups may comprise part of a single ligand;    -   R^(q) is selected from optionally substituted C₁₋₁₂ aliphatic        and optionally substituted aryl;    -   M is a metal atom;    -   Q′ is any ligand and need not be present;    -   d is an integer between 0 and 8 inclusive;    -   e is an integer between 1 and 6 inclusive;    -   w is a number such as to provide the stable anionic metal        carbonyl complex; and    -   y is the charge of the metal carbonyl anion.

In certain embodiments, the metal carbonyl anion in the aluminum-basedcarbonylation catalyst produced in the methods above comprises amonoanionic carbonyl complex of any metal from group 5, 7, or 9 of theperiodic table or a dianionic carbonyl complex of any metal from group 4or 8 of the periodic table. It should be understood that in cases wherethe metal carbonyl anion is dianionic, there will typically be twoaluminum complexes associated with each dianionic metal carbonyl. Insome embodiments, the metal carbonyl anion contains cobalt or manganese.In some embodiments, the metal carbonyl anion contains rhodium.Exemplary metal carbonyl anions include, but are not limited to:[Co(CO)₄]⁻, [Ti(CO)₆]²⁻, [V(CO)₆]⁻, [Rh(CO)₄]⁻, [Fe(CO)₄]²⁻,[Ru(CO)₄]²⁻, [Os(CO)₄]²⁻, [Cr₂(CO)₁₀]²⁻, [Fe₂(CO)₈]²⁻, [Tc(CO)₅]⁻,[Re(CO)₅]⁻, and [Mn(CO)₅]⁻. In certain embodiments, the metal carbonylanion comprises [Co(CO)₄]⁻. In some embodiments, a mixture of two ormore metal carbonyl anions may be present.

The term “such as to provide a stable anionic metal carbonyl” for w inmetal carbonyl anions of formula [Q′_(d)M_(e)(CO)_(w)]^(y−) is usedherein to mean that [Q′_(d)M_(e)(CO)_(w)]^(y−) is a speciescharacterizable by analytical means, e.g., NMR, IR, X-raycrystallography, Raman spectroscopy and/or electron spin resonance (EPR)or isolable in the presence of a suitable cation, or a species formed insitu. It is to be understood that metals which can form stable metalcarbonyl complexes have known coordinative capacities and propensitiesto form polynuclear complexes which, together with the number andcharacter of optional ligands Q′ that may be present and the charge onthe complex will determine the number of sites available for CO tocoordinate and therefore the value of w. Typically, such compoundsconform to the “18-electron rule”. Such knowledge is within the grasp ofone having ordinary skill in the arts pertaining to the synthesis andcharacterization of metal carbonyl compounds.

In certain embodiments, one or more of the CO ligands of any of themetal carbonyl anions described above is replaced with a ligand Q′. Incertain embodiments, Q′ is a phosphine ligand. In certain embodiments,Q′ is a triaryl phosphine. In certain embodiments, Q′ is trialkylphosphine. In certain embodiments, Q′ is a phosphite ligand. In certainembodiments, Q′ is an optionally substituted cyclopentadienyl ligand. Incertain embodiments, Q′ is cp (e.g., cyclopentadienyl). In certainembodiments, Q′ is cp* (e.g., pentamethylcyclopentadienyl).

As described above, R^(q) is an optionally substituted aliphatic groupor aryl group. In certain embodiments, R^(q) is a C₁₋₁₂ aliphatic group.In certain embodiments, R^(q) is a C₁₋₈ aliphatic group. In certainembodiments, R^(q) is a C₁₋₆ aliphatic group. In certain embodiments,R^(q) is a C₁₋₄ aliphatic group.

In certain embodiments, R^(q) is selected from the group consisting ofmethyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and octyl. Incertain embodiments, R^(q) is methyl. In certain embodiments, R^(q) isethyl. In certain embodiments, R^(q) is i-propyl. In certainembodiments, R^(q) is i-butyl. In certain embodiments, R^(q) is n-butyl.In certain embodiments, R^(q) is n-hexyl. In certain embodiments, R^(q)is n-octyl. In certain embodiments, R^(q) is ethyl. In certainembodiments, R^(q) is methyl.

In certain embodiments, R^(q) corresponds to an alkyl group of anavailable trialkyl aluminum compound. Several trialkylaluminum reagentsare commercially available and processes for the preparationtrialkylaluminum reagents are well known in the art: for example, bymethods described in U.S. Pat. Nos. 3,006,942 and 3,960,912 (thecontents of each of which are incorporated herein by reference). In someembodiments, a trialkylaluminum reagent is trimethylaluminum. In someembodiments, a trialkylaluminum reagent is triethylaluminum. In someembodiments, a trialkylaluminum reagent is tripropylaluminum. In someembodiments, a trialkylaluminum reagent is triisobutylaluminum. In someembodiments, a trialkylaluminum reagent is trioctylaluminum. In certainembodiments, the step of contacting the compound of formula I with aneutral metal carbonyl is performed in the presence one or moresolvents. In certain embodiments, the provided organic solvent isselected from aliphatic hydrocarbons, aromatic hydrocarbons, halogenatedsolvents, ethers, esters, ketones, nitriles, amides, carbonates,alcohols, amines, sulfones, or mixtures of any two or more of these. Incertain embodiments, the organic solvent comprises an ether. In certainembodiments, an ether is selected from diethyl ether, methy-t-butylether, tetrahydrofuran, 1,4-dioxane, glyme, diglyme, triglyme, higherglymes, or mixtures of any two or more of these. In certain embodiments,the organic solvent comprises a hydrocarbon. In certain embodiments, thehydrocarbon is a C₅₋₂₀ aliphatic hydrocarbon solvent. In certainembodiments, the aliphatic hydrocarbon is selected from pentanes,hexanes, heptanes, and mixtures of higher aliphatic hydrocarbons. Incertain embodiments, the hydrocarbon is an aromatic hydrocarbon solvent.In certain embodiments, the aromatic hydrocarbon is selected frombenzene, toluene, xylenes, mesitylene, halogenated aromatics, andcompositions comprising mixtures of aromatic hydrocarbons.

In certain embodiments where the contacting step is performed in thepresence of a solvent, one or both of compound I and the metal carbonylare provided as solutions in the organic solvent. In certainembodiments, compound I and the metal carbonyl are each provided assolutions in the same solvent or mixture of solvents. In certainembodiments, compound I and the metal carbonyl are both provided assolutions in an ether. In certain embodiments, compound I and the metalcarbonyl are both provided as solutions in 1,4-dioxane. In certainembodiments, compound I and the metal carbonyl are both provided assolutions in tetrahydrofuran. In certain embodiments, compound I and themetal carbonyl are both provided as solutions in diglyme.

In certain embodiments where the contacting step is performed in ahydrocarbon solvent, compound I is at least partially insoluble and ispresent as a suspension or slurry. In certain embodiments, the metalcarbonyl compound is substantially soluble in the hydrocarbon solvent.In certain embodiments, where compound I is present as a slurry orsuspension, the product catalyst is obtained as an insoluble solid.

In certain embodiments where the contacting step is performed in thepresence of a solvent, the product of the method is a homogenoussolution of the aluminum cobaltate catalyst. In certain embodimentswhere the contacting step is performed in the presence of a solvent, themethod comprises one or more additional steps to isolate the catalyst.Such isolation processes are well known in the art and may include stepssuch removing solvent, crystallizing the product, precipitating theproduct, extracting the product, or combinations of any two or more ofthese.

In certain embodiments, a neutral metal carbonyl compound provided inany of the methods herein has the general formula Q′_(d)M_(e)(CO)_(w′),where each Q′, M, d, and e, is as defined above and in the classes andsubclasses herein and w′ is a number such as to provide a stable neutralmetal carbonyl complex. In certain embodiments, a neutral metal carbonylhas the general formula Q′M(CO)_(w′). In certain embodiments, a neutralmetal carbonyl has the general formula M(CO)_(w′). In certainembodiments, a neutral metal carbonyl has the general formulaQ′M₂(CO)_(w′). In certain embodiments, a neutral metal carbonyl has thegeneral formula M₂(CO)_(w′). Suitable neutral metal carbonyl compoundsinclude, but are not limited to: Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆, Mo(CO)₆,W(CO)₆, Mn₂(CO)₁₀, Tc₂(CO)₁₀, Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅, Os(CO)₅,Ru₃(CO)₁₂, Os₃(CO)₁₂, Fe₃(CO)₁₂, Fe₂(CO)₉, Co₄(CO)₁₂, Rh₄(CO)₁₂,Rh₆(CO)₁₆, Ir₄(CO)₁₂, Co₂(CO)₈, and Ni(CO)₄. The term “such as toprovide a stable neutral metal carbonyl” for Q′_(d)M_(e)(CO)_(w′) isused herein to mean that Q′_(d)M_(e)(CO)_(w′) is a speciescharacterizable by analytical means, e.g., NMR, IR, X-raycrystallography, Raman spectroscopy and/or electron spin resonance (EPR)and isolable in pure form or a species formed in situ. It is to beunderstood that metals which can form stable metal carbonyl complexeshave known coordinative capacities and propensities to form polynuclearcomplexes which, together with the number and character of optionalligands Q that may be present will determine the number of sitesavailable for CO to coordinate and therefore the value of w′. Typically,such compounds conform to stoichiometries conforming to the “18-electronrule”. Such knowledge is within the grasp of one having ordinary skillin the arts pertaining to the synthesis and characterization of metalcarbonyl compounds.

In certain embodiments, one or more of the CO ligands of any of theneutral metal carbonyl compounds described above is replaced with aligand Q′. In certain embodiments, Q′ is a phosphine ligand. In certainembodiments, Q′ is a triaryl phosphine. In certain embodiments, Q′ istrialkyl phosphine. In certain embodiments, Q′ is a phosphite ligand. Incertain embodiments, Q′ is an optionally substituted cyclopentadienylligand. In certain embodiments, Q′ is cp. In certain embodiments, Q′ iscp*.

In certain embodiments, a provided neutral metal carbonyl compound inthe methods herein comprises a cobalt carbonyl compound. In certainembodiments, a provided neutral metal carbonyl compound is Co₂(CO)₈. Incertain embodiments, a provided neutral metal carbonyl compound isCo₄(CO)₁₂. In certain embodiments, a provided neutral metal carbonylcompound is a mixture of two or more cobalt carbonyl species.

Therefore, in certain embodiments, the present invention providesmethods for preparing an aluminum-based carbonylation catalyst offormula:

the method comprising a step of contacting a compound of formula I:

with a neutral cobalt carbonyl compound,where each of Q and R^(q) is as defined above and in the classes andsubclasses herein.

In certain embodiments, the molar ratio of compound I to the neutralmetal carbonyl compound is in the range of from about 0.1:1 to about10:1. In certain embodiments, the molar ratio of compound I to theneutral metal carbonyl compound is in the range of from 0.1:1 to 2:1; orfrom 0.5:1 to 1.5:1; or from 0.7:1 to 1.5:1; or from 0.8:1 to 1.2:1; orfrom 0.9:1 to 1.1:1. In certain embodiments, the molar ratio of compoundI to the neutral metal carbonyl compound is in the range of from 1:1 to5:1; or from 1:1 to 4:1; or from 1:1 to 3:1; or from 1:1 to 2:1; or from1.2:1 to 2.5:1; or from 1.4:1 to 2:1; or from 1.2:1 to 2:1; or from1.5:1 to 2:1.

In certain embodiments, the molar ratio of compound I to a neutral metalcarbonyl compound is controlled in the methods herein such that themolar ratio of metal atoms in a provided neutral metal carbonyl compoundto aluminum atoms in a provided compound I is in the range of about0.5:1 to about 2:1. For example, if a neutral metal carbonyl compound isdicobalt octacarbonyl, and compound I is an aluminum porphyrin complex,a 1:2 molar ratio of a neutral metal carbonyl to compound I wouldprovide a 1:1 molar ratio of cobalt to aluminum atoms. In certainembodiments, the molar ratio of metal atoms in a provided neutral metalcarbonyl compound to aluminum atoms in a provided compound I is in therange of from about 0.5:1 to about 1.5:1, or from about 0.7:1 to about1.3:1, or from about 0.8:1 to about 1.2:1, or from about 0.9:1 to about1.2:1, or from about 0.9:1 to about 1.1:1, or from about 0.95:1 to about1.05:1. In certain embodiments, the molar ratio of metal atoms in aprovided neutral metal carbonyl compound to aluminum atoms in a providedcompound I is in the range of from about 1:1 to about 2:1, or from about1:1 to about 1.8:1, or from about 1:1 to about 1.5:1, or from about 1:1to about 1.4:1, or from about 1:1 to about 1.3:1, or from about 1:1 toabout 1.2:1 or from about 1:1 to about 1.1:1.

In certain embodiments, the molar ratio of compound I to a neutral metalcarbonyl compound is controlled in the methods herein such that themolar ratio of metal atoms in a provided neutral metal carbonyl compoundto aluminum atoms in the provided compound I is about 1:1.

In certain embodiments, the step of contacting a compound of formula Iwith a neutral metal carbonyl compound entails adding compound I to avessel containing a neutral metal carbonyl compound. In certainembodiments, compound I is added to the vessel as a solution in anorganic solvent (vide supra). In certain embodiments, a neutral metalcarbonyl present in the vessel to which compound I is added is presentas a solution in an organic solvent. In certain embodiments, compound Iis added as a solid or a slurry to the vessel containing a neutral metalcarbonyl compound. In certain embodiments, a neutral metal carbonylcompound is present as a solid or a slurry in the vessel to whichcompound I is added.

In certain embodiments, the step of contacting a compound of formula Iwith a neutral metal carbonyl compound entails adding the neutral metalcarbonyl compound to a vessel containing compound I. In certainembodiments, a neutral metal carbonyl compound is added to the vessel asa solution in an organic solvent (vide supra). In certain embodiments,compound I is present in the vessel to which a neutral metal carbonylcompound is added as a solution in an organic solvent. In certainembodiments, a neutral metal carbonyl compound is added as a solid or aslurry to the vessel containing the compound of formula I. In certainembodiments, a compound of formula I is present as a solid or a slurryin the vessel to which the neutral metal carbonyl compound is added.

In certain embodiments, the step of contacting a compound of formula Iwith a neutral metal carbonyl compound entails simultaneously adding theneutral metal carbonyl compound and compound I to a vessel. In certainembodiments, a neutral metal carbonyl compound is added to the vessel asa solution in an organic solvent (vide supra). In certain embodiments, aneutral metal carbonyl compound is added to the vessel as a solid or aslurry. In certain embodiments, compound I is added to the vessel as asolution in an organic solvent (vide supra). In certain embodiments,compound I is added to the vessel as a solid or a slurry. In certainembodiments, compound I and a neutral metal carbonyl are each added tothe vessel as solutions in an organic solvent. In certain embodiments,the solutions are combined enroute to the vessel—e.g. by using a mixingtee or flowing the combined solutions through a static mixer.

In certain embodiments, compound I and a neutral metal carbonyl compoundare contacted under an atmosphere comprising CO. In certain embodiments,the CO is present at a pressure from about 1 atmosphere to about 400atmospheres. In certain embodiments, compound I and a neutral metalcarbonyl compound are contacted under an atmosphere comprising CO at apressure between about 1 atmosphere and about 100 atmospheres, orbetween about 1 atmosphere and about 50 atmospheres, or between about 10atmospheres and about 20 atmospheres, or between about 5 atmospheres andabout 10 atmospheres, or between about 1 atmosphere and about 5atmospheres.

In certain embodiments, the step of contacting compound I with a neutralmetal carbonyl includes heating. In certain embodiments, the contactingstep is performed at a temperature between about 30° C. and about 250°C. In certain embodiments, the contacting step is performed at between30 and 200° C., between 30 and 150° C., between 30 and 100° C., between30 and 80° C., between 40 and 100° C., between 50 and 100° C., between100 and 200° C., between 100 and 150° C., or between 30 and 50° C.

In certain embodiments, the methods in section I(a) are characterized inthat a product of the contacting step is a ketone of formula (R^(q))₂COwhere R^(q) is as defined above and in the classes and subclassesherein.

Therefore, in certain embodiments, the present invention encompasses amethod of preparing an aluminum-based carbonylation catalyst of formula:

and a ketone of formula

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound,where each of Q, R^(q), Q′, M, d, e, w, and y is as defined above and inthe classes and subclasses herein.

I(b) Methods Based on Aluminum Carboxylates

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I′:

with a neutral metal carbonyl compound,where each of Q, M, Q′, d, e, w, and y is as defined above and in theclasses and subclasses herein, and R^(q′) is selected from —H,optionally substituted C₁₋₄₀ aliphatic and optionally substituted aryl.

In certain embodiments, the metal carbonyl anion([Q′_(d)M_(e)(CO)_(w)]^(y−)) in the aluminum-based carbonylationcatalyst produced in the methods above comprises a monoanionic carbonylcomplex of any metal from group 5, 7 or 9 of the periodic table or adianionic carbonyl complex of any metal from group 4 or 8 of theperiodic table. It should be understood that in cases where the metalcarbonyl anion is dianionic, there will typically be two aluminumcomplexes associated with each dianionic metal carbonyl. In someembodiments, the metal carbonyl anion contains cobalt or manganese. Insome embodiments, the metal carbonyl anion contains rhodium. Exemplarymetal carbonyl anions include, but are not limited to: [Co(CO)₄]⁻,[Ti(CO)₆]²⁻, [V(CO)₆]⁻, [Rh(CO)₄]⁻, [Fe(CO)₄]²⁻, [Ru(CO)₄]²⁻,[Os(CO)₄]²⁻, [Cr₂(CO)₁₀]²⁻, [Fe₂(CO)₈]²⁻, [Tc(CO)₅]⁻, [Re(CO)₅]⁻, and[Mn(CO)₅]⁻. In certain embodiments, the metal carbonyl anion comprises[Co(CO)₄]⁻. In some embodiments, a mixture of two or more metal carbonylanions may be present.

The term “such as to provide a stable anionic metal carbonyl” for w inmetal carbonyl anions of formula [Q′_(d)M_(e)(CO)_(w)]^(y−) is usedherein to mean that [Q′_(d)M_(e)(CO)_(w)]^(y−) is a speciescharacterizable by analytical means, e.g., NMR, IR, X-raycrystallography, Raman spectroscopy and/or electron spin resonance (EPR)or isolable in the presence of a suitable cation, or a species formed insitu. It is to be understood that metals which can form stable metalcarbonyl complexes have known coordinative capacities and propensitiesto form polynuclear complexes which, together with the number andcharacter of optional ligands Q′ that may be present and the charge onthe complex will determine the number of sites available for CO tocoordinate and therefore the value of w. Typically, such compoundsconform to the “18-electron rule”. Such knowledge is within the grasp ofone having ordinary skill in the arts pertaining to the synthesis andcharacterization of metal carbonyl compounds.

In certain embodiments, one or more of the CO ligands of any of themetal carbonyl anions described above is replaced with a ligand Q′. Incertain embodiments, Q′ is a phosphine ligand. In certain embodiments,Q′ is a triaryl phosphine. In certain embodiments, Q′ is trialkylphosphine. In certain embodiments, Q′ is a phosphite ligand. In certainembodiments, Q′ is an optionally substituted cyclopentadienyl ligand. Incertain embodiments, Q′ is cp. In certain embodiments, Q′ is cp*.

As described above, R^(q′) is selected from the group consisting ofhydrogen, an optionally substituted aliphatic group or an optionallysubstituted aryl group. In certain embodiments, R^(q′) is a C₁₋₄₀aliphatic group. In certain embodiments, R^(q′) is a C₁₋₂₀ aliphaticgroup. In certain embodiments, R^(q) is a C₁₋₈ aliphatic group. R^(q) isa substituted C₁₋₈ aliphatic group. In certain embodiments, R^(q′) is aC₁₋₁₂ aliphatic group. In certain embodiments, R^(q′) is a C₁₋₆aliphatic group. In certain embodiments, R^(q′) is a C₁₋₄ aliphaticgroup.

In certain embodiments, R^(q′) is —H. In certain embodiments, R^(q′) isselected from the group consisting of methyl, ethyl, n-propyl, i-propyl,n-butyl, i-butyl, and octyl. In certain embodiments, R^(q′) is selectedfrom the group consisting of chloromethyl, dichloromethyl,trichloromethyl, trifluoromethyl 1,1,1-trifluoromethyl, andpentafluoromethyl. In certain embodiments, R^(q′) is methyl. In certainembodiments, R^(q′) is ethyl. In certain embodiments, R^(q′) isi-propyl. In certain embodiments, R^(q′) is i-butyl. In certainembodiments, R^(q′) is n-butyl. In certain embodiments, R^(q′) isn-hexyl. In certain embodiments, R^(q′) is n-octyl. In certainembodiments, R^(q′) is a C₈₋₃₂ fatty acid chain.

In certain embodiments, R^(q′) is an optionally substituted aromaticgroup. In certain embodiments, R^(q′) is phenyl. In certain embodiments,R^(q′) is selected from the group consisting of: phenyl, o-toluyl,m-toluyl, p-toluyl, chlorophenyl, and nitrophenyl. In certainembodiments, R^(q′) is phenyl. In certain embodiments, R^(q′) issubstituted phenyl.

In certain embodiments, the step of contacting a compound of formula I′with a neutral metal carbonyl is performed in the presence one or moresolvents. In certain embodiments, the provided organic solvent isselected from aliphatic hydrocarbons, aromatic hydrocarbons, halogenatedsolvents, ethers, esters, ketones, nitriles, amides, carbonates,alcohols, amines, sulfones, or mixtures of any two or more of these. Incertain embodiments, the organic solvent comprises an ether. In certainembodiments, an ether is selected from diethyl ether, methy-t-butylether, tetrahydrofuran, 1,4-dioxane, glyme, diglyme, triglyme, higherglymes, or mixtures of any two or more of these. In certain embodiments,the organic solvent comprises a hydrocarbon. In certain embodiments, thehydrocarbon is a C₅₋₂₀ aliphatic hydrocarbon solvent. In certainembodiments, the aliphatic hydrocarbon is selected from pentanes,hexanes, heptanes, and liquid mixtures of higher aliphatic hydrocarbons.In certain embodiments, the hydrocarbon is an aromatic hydrocarbonsolvent. In certain embodiments, the aromatic hydrocarbon is selectedfrom benzene, toluene, xylenes, mesitylene, halogenated aromatics, andcompositions comprising mixtures of aromatic hydrocarbons.

In certain embodiments where the contacting step is performed in thepresence of a solvent, one or both of compound I′ and a metal carbonylare provided as solutions in the organic solvent. In certainembodiments, compound I′ and a metal carbonyl are each provided assolutions in the same solvent or mixture of solvents. In certainembodiments, compound I′ and a metal carbonyl are both provided assolutions in an ether. In certain embodiments, compound I′ and the metalcarbonyl are both provided as solutions in 1,4-dioxane. In certainembodiments, compound I′ and the metal carbonyl are both provided assolutions in tetrahydrofuran. In certain embodiments, compound I′ andthe metal carbonyl are both provided as solutions in diglyme.

In certain embodiments where the contacting step is performed in ahydrocarbon solvent, compound I′ is at least partially insoluble and ispresent as a suspension or slurry. In certain embodiments, a metalcarbonyl compound is substantially soluble in the hydrocarbon solvent.In certain embodiments, where compound I′ is present as a slurry orsuspension, a product catalyst is obtained as an insoluble solid.

In certain embodiments where the contacting step is performed in thepresence of a solvent, the product of the method is a homogenoussolution of the aluminum cobaltate catalyst. In certain embodimentswhere the contacting step is performed in the presence of a solvent, themethod comprises one or more additional steps to isolate the catalyst.Such isolation processes are well known in the art and may include stepssuch as removing solvent, crystallizing the product, precipitating theproduct, extracting the product, or combinations of any two or more ofthese.

In certain embodiments, a neutral metal carbonyl compound provided inany of the methods herein has the general formula Q′_(d)M_(e)(CO)_(w′),where each Q′, M, d, and e, is as defined above and in the classes andsubclasses herein and w′ is a number such as to provide a stable neutralmetal carbonyl complex. In certain embodiments, a neutral metal carbonylhas the general formula Q′M(CO)_(w′). In certain embodiments, a neutralmetal carbonyl has the general formula M(CO)_(w′). In certainembodiments, a neutral metal carbonyl has the general formulaQ′M₂(CO)_(w′). In certain embodiments, a neutral metal carbonyl has thegeneral formula M₂(CO)_(w′). Suitable neutral metal carbonyl compoundsinclude, but are not limited to: Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆, Mo(CO)₆,W(CO)₆, Mn₂(CO)₁₀, Tc₂(CO)₁₀, Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅, Os(CO)₅,Ru₃(CO)₁₂, Os₃(CO)₁₂, Fe₃(CO)₁₂, Fe₂(CO)₉, Co₄(CO)₁₂, Rh₄(CO)₁₂,Rh₆(CO)₁₆, Ir₄(CO)₁₂, Co₂(CO)₈, and Ni(CO)₄.

The term “such as to provide a stable neutral metal carbonyl” forQ′_(d)M_(e)(CO)_(w′) is used herein to mean that Q′_(d)M_(e)(CO)_(w′) isa species characterizable by analytical means, e.g., NMR, IR, X-raycrystallography, Raman spectroscopy and/or electron spin resonance (EPR)and isolable in pure form or a species formed in situ. It is to beunderstood that metals which can form stable metal carbonyl complexeshave known coordinative capacities and propensities to form polynuclearcomplexes which, together with the number and character of optionalligands Q that may be present will determine the number of sitesavailable for CO to coordinate and therefore the value of w′. Typically,such compounds conform to stoichiometries conforming to the “18-electronrule”. Such knowledge is within the grasp of one having ordinary skillin the arts pertaining to the synthesis and characterization of metalcarbonyl compounds.

In certain embodiments, one or more of the CO ligands of any of themetal carbonyl compounds described above is replaced with a ligand Q′.In certain embodiments, Q′ is a phosphine ligand. In certainembodiments, Q′ is a triaryl phosphine. In certain embodiments, Q′ istrialkyl phosphine. In certain embodiments, Q′ is a phosphite ligand. Incertain embodiments, Q′ is an optionally substituted cyclopentadienylligand. In certain embodiments, Q′ is cp (e.g., cyclopentadienyl). Incertain embodiments, Q′ is cp* (e.g., pentamethylcyclopentadienyl).

In certain embodiments, a provided neutral metal carbonyl compound inthe methods herein comprises a cobalt carbonyl compound. In certainembodiments, a provided neutral metal carbonyl compound is Co₂(CO)₈. Incertain embodiments, a provided neutral metal carbonyl compound isCo₄(CO)₁₂. In certain embodiments, a provided neutral metal carbonylcompound is a mixture of two or more cobalt carbonyl species.

Therefore, in certain embodiments, the present invention providesmethods for preparing an aluminum-based carbonylation catalyst offormula:

the method comprising a step of contacting a compound of formula I′:

with a neutral cobalt carbonyl compound,where each of Q and R^(q′) is as defined above and in the classes andsubclasses herein.

In certain embodiments, the molar ratio of compound I′ to a neutralmetal carbonyl compound is in the range of from about 0.1:1 to about10:1. In certain embodiments, the molar ratio of compound I′ to aneutral metal carbonyl compound is in the range of from 0.1:1 to 2:1; orfrom 0.5:1 to 1.5:1; or from 0.7:1 to 1.5:1; or from 0.8:1 to 1.2:1; orfrom 0.9:1 to 1.1:1. In certain embodiments, the molar ratio of compoundI′ to a neutral metal carbonyl compound is in the range of from 1:1 to5:1; or from 1:1 to 4:1; or from 1:1 to 3:1; or from 1:1 to 2:1; or from1.2:1 to 2.5:1; or from 1.4:1 to 2:1; or from 1.2:1 to 2:1; or from1.5:1 to 2:1.

In certain embodiments, the molar ratio of compound I′ to a neutralmetal carbonyl compound is controlled in the methods herein such thatthe molar ratio of metal atoms in the provided neutral metal carbonylcompound to aluminum atoms in the provided compound I′ is in the rangeof about 0.5:1 to about 2:1. For example, if a neutral metal carbonylcompound is dicobalt octacarbonyl, and compound I′ is an aluminumporphyrin complex, a 1:2 molar ratio of a neutral metal carbonyl tocompound I′ would provide a 1:1 molar ratio of cobalt to aluminum atoms.In certain embodiments, the molar ratio of metal atoms in the providedneutral metal carbonyl compound to aluminum atoms in the providedcompound I′ is in the range of from about 0.5:1 to about 1.5:1, or fromabout 0.7:1 to about 1.3:1, or from about 0.8:1 to about 1.2:1, or fromabout 0.9:1 to about 1.2:1, or from about 0.9:1 to about 1.1:1, or fromabout 0.95:1 to about 1.05:1. In certain embodiments, the molar ratio ofmetal atoms in the provided neutral metal carbonyl compound to aluminumatoms in the provided compound I′ is in the range of from about 1:1 toabout 2:1, or from about 1:1 to about 1.8:1, or from about 1:1 to about1.5:1, or from about 1:1 to about 1.4:1, or from about 1:1 to about1.3:1, or from about 1:1 to about 1.2:1 or from about 1:1 to about1.1:1.

In certain embodiments, the molar ratio of compound I′ to a neutralmetal carbonyl compound is controlled in the methods herein such thatthe molar ratio of metal atoms in the provided neutral metal carbonylcompound to aluminum atoms in the provided compound I′ is about 1:1.

In certain embodiments, the step of contacting a compound of formula I′with a neutral metal carbonyl compound entails adding compound I′ to avessel containing a neutral metal carbonyl compound. In certainembodiments, compound I′ is added to the vessel as a solution in anorganic solvent (vide supra). In certain embodiments, a neutral metalcarbonyl present in the vessel to which compound I′ is added is presentas a solution in an organic solvent. In certain embodiments, compound I′is added as a solid or a slurry to the vessel containing a neutral metalcarbonyl compound. In certain embodiments, a neutral metal carbonylcompound is present as a solid or a slurry in the vessel to whichcompound I′ is added.

In certain embodiments, the step of contacting a compound of formula I′with a neutral metal carbonyl compound entails adding the neutral metalcarbonyl compound to a vessel containing compound I′. In certainembodiments, a neutral metal carbonyl compound is added to the vessel asa solution in an organic solvent (vide supra). In certain embodiments,compound I′ is present in the vessel to which a neutral metal carbonylcompound is added as a solution in an organic solvent. In certainembodiments, a neutral metal carbonyl compound is added as a solid or aslurry to the vessel containing the compound of formula I′. In certainembodiments, a compound of formula I′ is present as a solid or a slurryin the vessel to which a neutral metal carbonyl compound is added.

In certain embodiments, the step of contacting a compound of formula I′with a neutral metal carbonyl compound entails simultaneously adding aneutral metal carbonyl compound and compound I′ to a vessel. In certainembodiments, a neutral metal carbonyl compound is added to the vessel asa solution in an organic solvent (vide supra). In certain embodiments, aneutral metal carbonyl compound is added to the vessel as a solid or aslurry. In certain embodiments, compound I′ is added to the vessel as asolution in an organic solvent (vide supra). In certain embodiments,compound I′ is added to the vessel as a solid or a slurry. In certainembodiments, compound I′ and a neutral metal carbonyl are each added tothe vessel as solutions in an organic solvent. In certain embodiments,the solutions are combined en route to the vessel—e.g. by using a mixingtee or flowing the combined solutions through a static mixer.

In certain embodiments, compound I′ and a neutral metal carbonylcompound are contacted under an atmosphere comprising CO. In certainembodiments, the CO is present at a pressure from about 1 atmosphere toabout 400 atmospheres. In certain embodiments, compound I′ and a neutralmetal carbonyl compound are contacted under an atmosphere comprising COat a pressure between about 1 atmosphere and about 100 atmospheres, orbetween about 1 atmosphere and about 50 atmospheres, or between about 10atmospheres and about 20 atmospheres, or between about 5 atmospheres andabout 10 atmospheres, or between about 1 atmosphere and about 5atmospheres.

In certain embodiments, the step of contacting compound I′ with aneutral metal carbonyl includes heating. In certain embodiments, thecontacting step is performed at a temperature between about 30° C. andabout 250° C. In certain embodiments, the contacting step is performedat between 30 and 200° C., between 30 and 150° C., between 30 and 100°C., between 30 and 80° C., between 40 and 100° C., between 50 and 100°C., between 100 and 200° C., between 100 and 150° C., or between 30 and50° C.

I(c) Contaminant Free Ionic Catalyst Compositions

In another aspect, the present invention encompasses the Applicant'srecognition that catalysts made utilizing the salt metathesis methods ofthe prior art (described above) are contaminated with alkali metal saltsand/or halides. Such contamination has been found to have undesirableeffects in continuous reaction systems where it can lead to formation ofprecipitates that can foul pumps and/or interfere with catalystrecycling systems. Contrary to expectation, these contamination problemshave been found to remain even after rigorous purification of catalystsmade by salt metathesis (for example after recrystallization of thecatalyst from organic solvents). In certain embodiments, the presentinvention encompasses methods of producing aluminum cobaltate catalyststhat are essentially free of halide impurities and/or essentially freeof alkali metal contaminants. Therefore, in certain embodiments, themethods described above (e.g. those described in sections I(a) and I(b))for preparing an aluminum-based carbonylation catalyst of formula:

wherein each of Q, Q′, M, d, e, w, and y is as defined above anddescribed in classes and subclasses herein, are characterized in thatthe catalyst compositions thus formed have little or no contaminationwith halide and/or alkali metal salts. In certain embodiments, themethods are characterized in that the catalyst composition formed isessentially free of halide. In certain embodiments, the methods arecharacterized in that they provide a catalyst composition having ahalide content less than about 200 ppm. In certain embodiments, themethods are characterized in that the catalyst composition formed has ahalide content less than about 150 ppm, less than about 100 ppm, lessthan about 50 ppm, less than about 40 ppm, less than about 30 ppm, lessthan about 20 ppm, less than about 10 ppm, less than about 5 ppm, lessthan about 2 ppm, or less than about 1 ppm. In certain embodiments, themethods are characterized in that the catalyst composition formed isessentially free of alkali metal salts. In certain embodiments, themethods are characterized in that the catalyst composition formed has analkali metal salt content less than about 200 ppm. In certainembodiments, the methods are characterized in that the catalystcomposition formed has an alkali metal salt content less than about 150ppm, less than about 100 ppm, less than about 50 ppm, less than about 40ppm, less than about 30 ppm, less than about 20 ppm, less than about 10ppm, less than about 5 ppm, less than about 2 ppm, or less than about 1ppm. It will be appreciated that the amounts of halide or alkali metalsalts in this paragraph refer to contaminant impurities or byproducts,not halogen atoms or counterions that are part of the desired catalyst.

II. Methods of Making Neutral Aluminum-Based Carbonylation Catalysts

In another aspect, the present invention provides methods ofsynthesizing neutral aluminum-based carbonylation catalysts.

II(a) Methods Based on Aluminum Alkyls or Aryls

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

-   -   where each of Q, M, Q′, R^(q), w, and d are as defined above and        in the classes and subclasses herein,    -   R^(a′) is hydrogen or an optionally substituted group selected        from the group consisting of C₁₋₃₀ aliphatic; C₁₋₃₀        heteroaliphatic having 1-4 heteroatoms independently selected        from the group consisting of nitrogen, oxygen, and sulfur; 6- to        10-membered aryl; 5- to 10-membered heteroaryl having 1-4        heteroatoms independently selected from nitrogen, oxygen, and        sulfur; and 4- to 7-membered heterocyclic having 1-3 heteroatoms        independently selected from the group consisting of nitrogen,        oxygen, and sulfur;    -   each of R^(b′), R^(c′), and R^(d′) is independently hydrogen or        an optionally substituted group selected from the group        consisting of C₁₋₁₂ aliphatic; C₁₋₁₂ heteroaliphatic having 1-4        heteroatoms independently selected from the group consisting of        nitrogen, oxygen, and sulfur; 6- to 10-membered aryl; 5- to        10-membered heteroaryl having 1-4 heteroatoms independently        selected from nitrogen, oxygen, and sulfur; and 4- to 7-membered        heterocyclic having 1-3 heteroatoms independently selected from        the group consisting of nitrogen, oxygen, and sulfur;    -   wherein any of (R^(b′) and R^(c′)), (R^(c′) and R^(d′)), and        (R^(a′) and R^(b′)) can be taken together with their intervening        atoms to form one or more rings selected from the group        consisting of: optionally substituted C₃-C₁₄ carbocycle,        optionally substituted C₃-C₁₄ heterocycle, optionally        substituted C₆-C₁₀ aryl, and optionally substituted C₅-C₁₀        heteroaryl.

In certain embodiments, a compound of formula I and a neutral metalcarbonyl compound are contacted in the presence of an epoxide selectedfrom the group consisting of: ethylene oxide, propylene oxide, 1,2butylene oxide, 2,3 butylene oxide, epoxides of higher alpha olefins,epichlorohydrin, glycidyl ethers, cyclohexene oxide, cyclopentene oxide,3-vinyl cyclohexene oxide, and 3-ethyl cyclohexene oxide.

In certain embodiments, a compound of formula I and a neutral metalcarbonyl compound are contacted in the presence of ethylene oxide.

In certain embodiments, a compound of formula I and a neutral metalcarbonyl compound are contacted in the presence of propylene oxide.

In certain embodiments, an epoxide is present in a molar excess relativeto compound I and a neutral metal carbonyl compound. In certainembodiments, an epoxide is present in at least a 2-fold molar excess, atleast a 5-fold molar excess, at least a 10-fold molar excess, at least a20-fold molar excess, at least a 50-fold molar excess, at least a100-fold molar excess, at least a 500-fold molar excess, or at least a1,000-fold molar excess, relative to compound I or a neutral metalcarbonyl compound.

In certain embodiments, a compound of formula I and a neutral metalcarbonyl compound are contacted under CO pressure. In certainembodiments, the CO pressure is in the range from about 1 atmosphere toabout 400 atmospheres. In certain embodiments, compound I and a neutralmetal carbonyl compound are contacted under an atmosphere comprising COat a pressure between about 2 atmospheres and about 100 atmospheres, orbetween about 5 atmosphere and about 50 atmospheres, or between about 10atmospheres and about 20 atmospheres, or between about 20 atmospheresand about 50 atmospheres, or between about 50 atmospheres and about 100atmospheres.

In certain embodiments of methods for synthesizing neutralaluminum-based carbonylation catalysts, a neutral metal carbonylcompound provided has the general formula Q′_(d)M_(e)(CO)_(w′), whereeach Q′, M, d, and e, is as defined above and in the classes andsubclasses herein and w′ is a number such as to provide a stable neutralmetal carbonyl complex. In certain embodiments, a neutral metal carbonylhas the general formula Q′M(CO)_(w′). In certain embodiments, a neutralmetal carbonyl has the general formula M(CO)_(w′). In certainembodiments, a neutral metal carbonyl has the general formulaQ′M₂(CO)_(w′). In certain embodiments, a neutral metal carbonyl has thegeneral formula M₂(CO)_(w′). Suitable neutral metal carbonyl compoundsinclude, but are not limited to: Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆, Mo(CO)₆,W(CO)₆, Mn₂(CO)₁₀, Tc₂(CO)₁₀, Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅, Os(CO)₅,Ru₃(CO)₁₂, Os₃(CO)₁₂, Fe₃(CO)₁₂, Fe₂(CO)₉, Co₄(CO)₁₂, Rh₄(CO)₁₂,Rh₆(CO)₁₆, Ir₄(CO)₁₂, Co₂(CO)₈, and Ni(CO)₄. The term “such as toprovide a stable neutral metal carbonyl” for Q′_(d)M_(e)(CO)_(w′) isused herein to mean that Q′_(d)M_(e)(CO)_(w′) is a speciescharacterizable by analytical means, e.g., NMR, IR, X-raycrystallography, Raman spectroscopy and/or electron spin resonance (EPR)and isolable in pure form or a species formed in situ. It is to beunderstood that metals which can form stable metal carbonyl complexeshave known coordinative capacities and propensities to form polynuclearcomplexes which, together with the number and character of optionalligands Q that may be present will determine the number of sitesavailable for CO to coordinate and therefore the value of w′. Typically,such compounds have stoichiometries conforming to the “18-electronrule”. Such knowledge is within the grasp of one having ordinary skillin the arts pertaining to the synthesis and characterization of metalcarbonyl compounds.

In certain embodiments, one or more of the CO ligands of any of themetal carbonyl compounds described above is replaced with a ligand Q′.In certain embodiments, Q′ is a phosphine ligand. In certainembodiments, Q′ is a triaryl phosphine. In certain embodiments, Q′ istrialkyl phosphine. In certain embodiments, Q′ is a phosphite ligand. Incertain embodiments, Q′ is an optionally substituted cyclopentadienylligand. In certain embodiments, Q′ is cp. In certain embodiments, Q′ iscp*.

In certain embodiments, a provided neutral metal carbonyl compound inthe methods comprises a cobalt carbonyl compound. In certainembodiments, a provided neutral metal carbonyl compound is Co₂(CO)₈. Incertain embodiments, a provided neutral metal carbonyl compound isCo₄(CO)₁₂. In certain embodiments, a provided neutral metal carbonylcompound is a mixture of two or more cobalt carbonyl species.

In certain embodiments, the step of contacting the compound of formula Iwith a neutral metal carbonyl is performed in the presence one or moresolvents in addition to the epoxide and CO. In certain embodiments, theprovided organic solvent is selected from aliphatic hydrocarbons,aromatic hydrocarbons, halogenated solvents, ethers, esters, ketones,nitriles, amides, carbonates, alcohols, amines, sulfones, or mixtures ofany two or more of these. In certain embodiments, the organic solventcomprises an ether. In certain embodiments, an ether is selected fromdiethyl ether, methy-t-butyl ether, tetrahydrofuran, 1,4-dioxane, glyme,diglyme, triglyme, higher glymes, or mixtures of any two or more ofthese.

In certain embodiments where the contacting step is performed in thepresence of a solvent, one or both of compound I and a metal carbonylare provided as solutions in the organic solvent. In certainembodiments, compound I and a metal carbonyl are each provided assolutions in the same solvent or mixture of solvents. In certainembodiments, compound I and a metal carbonyl are both provided assolutions in an ether. In certain embodiments, compound I and a metalcarbonyl are both provided as solutions in 1,4-dioxane. In certainembodiments, compound I and a metal carbonyl are both provided assolutions in tetrahydrofuran. In certain embodiments, compound I and ametal carbonyl are both provided as solutions in diglyme.

In certain embodiments, a neutral metal carbonyl compound is provided asa solution in the epoxide.

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising the step of contacting a compound of formula I:

with a neutral cobalt carbonyl compound in the presence of ethyleneoxide and carbon monoxide, where each of Q and R^(q) is as defined aboveand in the classes and subclasses herein.

In certain embodiments, a neutral cobalt carbonyl compound comprisesdicobalt octacarbonyl. In certain embodiments, a neutral cobalt carbonylcompound comprises tetracobalt dodecacarbonyl. In certain embodiments, aneutral cobalt carbonyl compound comprises a mixture of two or morecobalt carbonyl species.

In certain embodiments, the molar ratio of compound I to the neutralmetal carbonyl compound is in the range of from about 0.1:1 to about10:1. In certain embodiments, the molar ratio of compound I to theneutral metal carbonyl compound is in the range of from 0.1:1 to 2:1; orfrom 0.5:1 to 1.5:1; or from 0.7:1 to 1.5:1; or from 0.8:1 to 1.2:1; orfrom 0.9:1 to 1.1:1. In certain embodiments, the molar ratio of compoundI to the neutral metal carbonyl compound is in the range of from 1:1 to5:1; or from 1:1 to 4:1; or from 1:1 to 3:1; or from 1:1 to 2:1; or from1.2:1 to 2.5:1; or from 1.4:1 to 2:1; or from 1.2:1 to 2:1; or from1.5:1 to 2:1.

In certain embodiments, the molar ratio of compound I to the neutralmetal carbonyl compound is controlled in the methods herein such thatthe molar ratio of metal atoms in the provided neutral metal carbonylcompound to aluminum atoms in the provided compound I is in the range ofabout 0.5:1 to about 2:1. For example, if the neutral metal carbonylcompound is dicobalt octacarbonyl, and compound I is an aluminumporphyrin complex, a 1:2 molar ratio of the neutral metal carbonyl tocompound I would provide a 1:1 molar ratio of cobalt to aluminum atoms.In certain embodiments, the molar ratio of metal atoms in the providedneutral metal carbonyl compound to aluminum atoms in the providedcompound I is in the range of from about 0.5:1 to about 1.5:1, or fromabout 0.7:1 to about 1.3:1, or from about 0.8:1 to about 1.2:1, or fromabout 0.9:1 to about 1.2:1, or from about 0.9:1 to about 1.1:1, or fromabout 0.95:1 to about 1.05:1. In certain embodiments, the molar ratio ofmetal atoms in the provided neutral metal carbonyl compound to aluminumatoms in the provided compound I is in the range of from about 1:1 toabout 2:1, or from about 1:1 to about 1.8:1, or from about 1:1 to about1.5:1, or from about 1:1 to about 1.4:1, or from about 1:1 to about1.3:1, or from about 1:1 to about 1.2:1 or from about 1:1 to about1.1:1.

In certain embodiments, the molar ratio of compound I to the neutralmetal carbonyl compound is controlled in the methods herein such thatthe molar ratio of metal atoms in a provided neutral metal carbonylcompound to aluminum atoms in a provided compound I is about 1:1.

In certain embodiments, the step of contacting compound I with a neutralmetal carbonyl includes heating. In certain embodiments, the contactingstep is performed at a temperature between about 30° C. and about 100°C. In certain embodiments, the contacting step is performed at atemperature between 30 and 80° C., between 40 and 100° C., between 50and 100° C., between 100 and 200° C., between 100 and 150° C., orbetween 30 and 50° C.

In certain embodiments, the methods in section II(a) are characterizedin that a product of the contacting step is a ketone of formula(R^(q))₂CO where R^(q) is as defined above and in the classes andsubclasses herein.

Therefore, in certain embodiments, the present invention encompasses amethod of preparing an aluminum-based carbonylation catalyst of formula:

and a ketone of formula

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

where each of Q, R^(q), Q′, R^(a′), R^(b′), R^(c′), R^(d′), d, e, w, andy is as defined above and in the classes and subclasses herein.

II(b) Methods Based on Aluminum Carboxylates

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

-   -   where each of Q, M, Q′, R^(q′), w, d R, R^(a′), R^(b′), R^(c′),        and R^(d′) are as defined above and in the classes and        subclasses herein,

In certain embodiments, a compound of formula I′ and a neutral metalcarbonyl compound are contacted in the presence of an epoxide selectedfrom the group consisting of: ethylene oxide, propylene oxide, 1,2butylene oxide, 2,3 butylene oxide, epoxides of higher alpha olefins,epichlorohydrin, glycidyl ethers, cyclohexene oxide, cyclopentene oxide,3-vinyl cyclohexene oxide, and 3-ethyl cyclohexene oxide.

In certain embodiments, a compound of formula I′ and a neutral metalcarbonyl compound are contacted in the presence of ethylene oxide.

In certain embodiments, a compound of formula I′ and a neutral metalcarbonyl compound are contacted in the presence of propylene oxide.

In certain embodiments, an epoxide is present in a molar excess relativeto compound I′ and a neutral metal carbonyl compound. In certainembodiments, an epoxide is present in at least a 2-fold molar excess, atleast a 5-fold molar excess, at least a 10-fold molar excess, at least a20-fold molar excess, at least a 50-fold molar excess, at least a100-fold molar excess, at least a 500-fold molar excess, at least a1,000-fold molar excess, relative to compound I′ or the neutral metalcarbonyl compound.

In certain embodiments, a compound of formula I′ and a neutral metalcarbonyl compound are contacted under CO pressure. In certainembodiments, the CO pressure is in the range from about 1 atmosphere toabout 400 atmospheres. In certain embodiments, compound I′ and a neutralmetal carbonyl compound are contacted under an atmosphere comprising COat a pressure between about 2 atmospheres and about 100 atmospheres, orbetween about 5 atmosphere and about 50 atmospheres, or between about 10atmospheres and about 20 atmospheres, or between about 20 atmospheresand about 50 atmospheres, or between about 50 atmospheres and about 100atmospheres.

In certain embodiments of methods for synthesizing neutralaluminum-based carbonylation catalysts, a neutral metal carbonylcompound provided has the general formula Q′_(d)M_(e)(CO)_(w′), whereeach Q′, M, d, and e, is as defined above and in the classes andsubclasses herein and w′ is a number such as to provide a stable neutralmetal carbonyl complex. In certain embodiments, a neutral metal carbonylhas the general formula Q′M(CO)_(w′). In certain embodiments, a neutralmetal carbonyl has the general formula M(CO)_(w′). In certainembodiments, a neutral metal carbonyl has the general formulaQ′M₂(CO)_(w′). In certain embodiments, a neutral metal carbonyl has thegeneral formula M₂(CO)_(w′). Suitable neutral metal carbonyl compoundsinclude, but are not limited to: Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆, Mo(CO)₆,W(CO)₆, Mn₂(CO)₁₀, Tc₂(CO)₁₀, Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅, Os(CO)₅,Ru₃(CO)₁₂, Os₃(CO)₁₂, Fe₃(CO)₁₂, Fe₂(CO)₉, Co₄(CO)₁₂, Rh₄(CO)₁₂,Rh₆(CO)₁₆, Ir₄(CO)₁₂, Co₂(CO)₈, and Ni(CO)₄. The term “such as toprovide a stable neutral metal carbonyl” for Q′_(d)M_(e)(CO)_(w′) isused herein to mean that Q′_(d)M_(e)(CO)_(w′) is a speciescharacterizable by analytical means, e.g., NMR, IR, X-raycrystallography, Raman spectroscopy and/or electron spin resonance (EPR)and isolable in pure form or a species formed in situ. It is to beunderstood that metals which can form stable metal carbonyl complexeshave known coordinative capacities and propensities to form polynuclearcomplexes which, together with the number and character of optionalligands Q′ that may be present will determine the number of sitesavailable for CO to coordinate and therefore the value of w′. Typically,such compounds conform to stoichiometries conforming to the “18-electronrule”. Such knowledge is within the grasp of one having ordinary skillin the arts pertaining to the synthesis and characterization of metalcarbonyl compounds.

In certain embodiments, one or more of the CO ligands of any of themetal carbonyl compounds described above is replaced with a ligand Q′.In certain embodiments, Q′ is a phosphine ligand. In certainembodiments, Q′ is a triaryl phosphine. In certain embodiments, Q′ istrialkyl phosphine. In certain embodiments, Q′ is a phosphite ligand. Incertain embodiments, Q′ is an optionally substituted cyclopentadienylligand. In certain embodiments, Q′ is cp. In certain embodiments, Q′ iscp*.

In certain embodiments, a provided neutral metal carbonyl compound inthe methods comprises a cobalt carbonyl compound. In certainembodiments, a provided neutral metal carbonyl compound is Co₂(CO)₈. Incertain embodiments, a provided neutral metal carbonyl compound isCo₄(CO)₁₂. In certain embodiments, a provided neutral metal carbonylcompound is a mixture of two or more cobalt carbonyl species.

As described above, R^(q′) is selected from the group consisting ofhydrogen, an optionally substituted aliphatic group or an optionallysubstituted aryl group. In certain embodiments, R^(q′) is a C₁₋₄₀aliphatic group. In certain embodiments, R^(q′) is a C₁₋₂₀ aliphaticgroup. In certain embodiments, R^(q′) is a C₁₋₈ aliphatic group. R^(q′)is a substituted C₁₋₈ aliphatic group. In certain embodiments, R^(q′) isa C₁₋₁₂ aliphatic group. In certain embodiments, R^(q′) is a C₁₋₆aliphatic group. In certain embodiments, R^(q′) is a C₁₋₄ aliphaticgroup.

In certain embodiments, R^(q′) is —H. In certain embodiments, R^(q′) isselected from the group consisting of methyl, ethyl, n-propyl, i-propyl,n-butyl, i-butyl, and octyl. In certain embodiments, R^(q′) is selectedfrom the group consisting of chloromethyl, dichloromethyl,trichloromethyl, trifluoromethyl 1,1,1-trifluoromethyl, andpentafluoromethyl. In certain embodiments, R^(q′) is methyl. In certainembodiments, R^(q′) is ethyl. In certain embodiments, R^(q′) isi-propyl. In certain embodiments, R^(q′) is i-butyl. In certainembodiments, R^(q′) is n-butyl. In certain embodiments, R^(q′) isn-hexyl. In certain embodiments, R^(q′) is n-octyl. In certainembodiments, R^(q′) is a C₈₋₃₂ fatty acid chain.

In certain embodiments, R^(q′) is an optionally substituted aromaticgroup. In certain embodiments, R^(q′) is phenyl. In certain embodiments,R^(q′) is selected from the group consisting of: phenyl, o-toluyl,m-toluyl, p-toluyl chlorophenyl, and nitrophenyl. In certainembodiments, R^(q′) is phenyl. In certain embodiments, R^(q′) issubstituted phenyl.

In certain embodiments, the step of contacting the compound of formulaI′ with a neutral metal carbonyl is performed in the presence one ormore solvents in addition to the epoxide and CO. In certain embodiments,a provided organic solvent is selected from aliphatic hydrocarbons,aromatic hydrocarbons, halogenated solvents, ethers, esters, ketones,nitriles, amides, carbonates, alcohols, amines, sulfones, or mixtures ofany two or more of these. In certain embodiments, an organic solventcomprises an ether. In certain embodiments, an ether is selected fromdiethyl ether, methy-t-butyl ether, tetrahydrofuran, 1,4-dioxane, glyme,diglyme, triglyme, higher glymes, or mixtures of any two or more ofthese.

In certain embodiments where the contacting step is performed in thepresence of a solvent, one or both of compound I′ and the metal carbonylare provided as solutions in the organic solvent. In certainembodiments, compound I′ and the metal carbonyl are each provided assolutions in the same solvent or mixture of solvents. In certainembodiments, compound I′ and a metal carbonyl are both provided assolutions in an ether. In certain embodiments, compound I′ and a metalcarbonyl are both provided as solutions in 1,4-dioxane. In certainembodiments, compound I′ and a metal carbonyl are both provided assolutions in tetrahydrofuran. In certain embodiments, compound I′ and ametal carbonyl are both provided as solutions in diglyme.

In certain embodiments, a neutral metal carbonyl compound is provided asa solution in an epoxide.

In certain embodiments, the present invention provides methods forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising the step of contacting a compound of formula I′:

with a neutral cobalt carbonyl compound in the presence of ethyleneoxide and carbon monoxide,where each of Q and R^(q′) is as defined above and in the classes andsubclasses herein, and x is such that a stable complex is formed. Insome embodiments, x is 3.

In certain embodiments, a neutral cobalt carbonyl compound comprisesdicobalt octacarbonyl. In certain embodiments, a neutral cobalt carbonylcompound comprises tetracobalt dodecacarbonyl. In certain embodiments, aneutral cobalt carbonyl compound comprises a mixture of two or morecobalt carbonyl species.

In certain embodiments, the molar ratio of compound I′ to the neutralmetal carbonyl compound is in the range of from about 0.1:1 to about10:1. In certain embodiments, the molar ratio of compound I′ to theneutral metal carbonyl compound is in the range of from 0.1:1 to 2:1; orfrom 0.5:1 to 1.5:1; or from 0.7:1 to 1.5:1; or from 0.8:1 to 1.2:1; orfrom 0.9:1 to 1.1:1. In certain embodiments, the molar ratio of compoundI′ to the neutral metal carbonyl compound is in the range of from 1:1 to5:1; or from 1:1 to 4:1; or from 1:1 to 3:1; or from 1:1 to 2:1; or from1.2:1 to 2.5:1; or from 1.4:1 to 2:1; or from 1.2:1 to 2:1; or from1.5:1 to 2:1.

In certain embodiments, the molar ratio of compound I′ to the neutralmetal carbonyl compound is controlled in the methods herein such thatthe molar ratio of metal atoms in the provided neutral metal carbonylcompound to aluminum atoms in the provided compound I′ is in the rangeof about 0.5:1 to about 2:1. For example, if the neutral metal carbonylcompound is dicobalt octacarbonyl, and compound I′ is an aluminumporphyrin complex, a 1:2 molar ratio of the neutral metal carbonyl tocompound I′ would provide a 1:1 molar ratio of cobalt to aluminum atoms.In certain embodiments, the molar ratio of metal atoms in the providedneutral metal carbonyl compound to aluminum atoms in the providedcompound I′ is in the range of from about 0.5:1 to about 1.5:1, or fromabout 0.7:1 to about 1.3:1, or from about 0.8:1 to about 1.2:1, or fromabout 0.9:1 to about 1.2:1, or from about 0.9:1 to about 1.1:1, or fromabout 0.95:1 to about 1.05:1. In certain embodiments, the molar ratio ofmetal atoms in the provided neutral metal carbonyl compound to aluminumatoms in the provided compound I′ is in the range of from about 1:1 toabout 2:1, or from about 1:1 to about 1.8:1, or from about 1:1 to about1.5:1, or from about 1:1 to about 1.4:1, or from about 1:1 to about1.3:1, or from about 1:1 to about 1.2:1 or from about 1:1 to about1.1:1.

In certain embodiments, the molar ratio of compound I′ to the neutralmetal carbonyl compound is controlled in the methods herein such thatthe molar ratio of metal atoms in the provided neutral metal carbonylcompound to aluminum atoms in the provided compound I′ is about 1:1.

In certain embodiments, the step of contacting compound I′ with theneutral metal carbonyl includes heating. In certain embodiments, thecontacting step is performed at a temperature between about 30° C. andabout 100° C. In certain embodiments, the contacting step is performedat a temperature between 30 and 80° C., between 40 and 100° C., between50 and 100° C., between 100 and 200° C., between 100 and 150° C., orbetween 30 and 50° C.

II(c) Contaminant-Free Neutral Catalyst Compositions

In certain embodiments, the methods described herein for preparing analuminum-based carbonylation catalyst of formula:

where each of Q, M, Q′, w, d, R^(a′), R^(b′), R^(c′), and R^(d′) are asdefined above and in the classes and subclasses herein, arecharacterized in that the catalysts thus formed have little or nocontamination with halide and/or alkali metal salts. In certainembodiments, the methods are characterized in that the catalyst formedis essentially free of halide. In certain embodiments, the methods arecharacterized in that the catalyst composition formed has a halidecontent less than about 200 ppm. In certain embodiments, the methods arecharacterized in that the catalyst composition formed has a halidecontent less than about 150 ppm, less than about 100 ppm, less thanabout 50 ppm, less than about 40 ppm, less than about 30 ppm, less thanabout 20 ppm, less than about 10 ppm, less than about 5 ppm, less thanabout 2 ppm, or less than about 1 ppm. In certain embodiments, themethods are characterized in that the catalyst composition formed isessentially free of alkali metal salts. In certain embodiments, themethods are characterized in that the catalyst composition formed has analkali metal salt content less than about 200 ppm. In certainembodiments, the methods are characterized in that the catalyst formedhas an alkali metal salt content less than about 150 ppm, less thanabout 100 ppm, less than about 50 ppm, less than about 40 ppm, less thanabout 30 ppm, less than about 20 ppm, less than about 10 ppm, less thanabout 5 ppm, less than about 2 ppm, or less than about 1 ppm. It will beappreciated that the amounts of halide or alkali metal salts in thisparagraph refer to contaminant impurities or byproducts, not halogenatoms or counterions that are part of the desired catalyst.

III. Methods for Providing Carbonylation Catalysts to EpoxideCarbonylation Reactions

In another aspect, the present invention encompasses methods forproviding carbonylation catalysts to an epoxide carbonylation reaction.In certain embodiments of such methods, the epoxide carbonylationreaction comprises a reaction zone where an epoxide (or mixture of twoor more epoxides) is contacted with carbon monoxide. In certainembodiments, such methods entail feeding the reaction zone withcarbonylation catalyst by providing two separate catalyst feed streams:a first catalyst feed stream containing a compound of formulae I or I′(as defined above and in the classes and subclasses herein) and a secondcatalyst feed stream containing a neutral metal carbonyl compound (asdefined above and in the classes and subclasses herein).

In certain embodiments, such methods comprise feeding the reaction zonewith a first catalyst feed stream containing a compound of formulae I orI′ (as defined above and in the classes and subclasses herein) and asecond catalyst feed stream containing a neutral cobalt carbonylcompound. In certain embodiments, such methods comprise feeding thereaction zone with a first catalyst feed stream containing a compound offormulae I or I′ (as defined above and in the classes and subclassesherein) and a second catalyst feed stream containing dicobaltoctacarbonyl. In certain embodiments, the first feed stream and thesecond feed stream are fed to the reaction zone at rates such thatapproximately equimolar amounts of cobalt and aluminum are fed to thereaction zone per unit time.

In certain embodiments, the epoxide carbonylation zone to which the twocatalyst feed streams is fed is part of a continuous epoxidecarbonylation process. In certain embodiments, the reaction zonecomprises a continuous epoxide carbonylation reactor. In certainembodiments, the continuous carbonylation reactor comprises one or morecontinuous stirred tank reactors (CSTRs). In certain embodiments, thecontinuous carbonylation reactor comprises one or more plug flowreactors (PFRs). In certain embodiments, the continuous carbonylationreactor is also fed with an epoxide feed stream and carbon monoxide.

In certain embodiments where the reaction zone is a continuous epoxidecarbonylation reactor, the continuous reactor is also fed with anepoxide feed stream and carbon monoxide. In some such embodiments, thefirst catalyst feed stream and the second catalyst feed stream are fedto the reaction zone at rates such that a molar ratio of epoxide tocarbonylation catalyst fed to the continuous reactor per unit time isbetween about 10 and about 100,000 moles of epoxide per mole ofcarbonylation catalyst. In certain embodiments, the molar ratio ofepoxide to carbonylation catalyst fed to the reactor per unit time isbetween about 50 and about 50,000, between about 100 and about 20,000,between about 100 and about 10,000, between about 100 and about 5,000,or between about 100 and about 2,500. In certain embodiments, the molarratio of epoxide to carbonylation catalyst fed to the reactor per unittime is between about 100 and about 50,000, between about 100 and about20,000, between about 100 and about 10,000, between about 100 and about5,000, or between about 100 and about 2,500. In certain embodiments, themolar ratio of epoxide to carbonylation catalyst fed to the reactor perunit time is between about 200 and about 20,000, between about 500 andabout 10,000, between about 500 and about 5,000, between about 1,000 andabout 5,000, between about 2,000 and about 5,000 between about 2,000 andabout 3,000, or between about 5,000 and about 10,000.

In certain embodiments, one or both of the first catalyst feedstream andthe second catalyst feedstream comprises solvent. In certainembodiments, such feed streams comprise an organic solvent selected fromthe group consisting of: aliphatic hydrocarbons, aromatic hydrocarbons,halogenated solvents, ethers, esters, ketones, nitriles, amides,carbonates, alcohols, amines, sulfones, or mixtures of any two or moreof these. In certain embodiments, such feed streams comprise one or moreethers. In certain embodiments, an ether is selected from diethyl ether,methy-t-butyl ether, tetrahydrofuran, 1,4-dioxane, glyme, diglyme,triglyme, higher glymes, or mixtures of any two or more of these. Incertain embodiments, such feed streams comprise 1,4-dioxane. In certainembodiments, such feed streams comprise tetrahydrofuran. In certainembodiments, such feed streams comprise diglyme.

In certain embodiments, the first catalyst feed stream comprises ahomogenous solution of an aluminum complex of formulae I or I′ in anorganic solvent. In certain embodiments, the first catalyst feed streamcomprises a slurry of an aluminum complex of formulae I or I′ in anorganic solvent. In certain embodiments, the first catalyst feed streamcomprises an ether. In certain embodiments, the first catalyst feedstream comprises 1,4-dioxane. In certain embodiments, such feed streamscomprise tetrahydrofuran. In certain embodiments, such feed streamscomprise diglyme.

In certain embodiments, the second catalyst feed stream comprises ahomogenous solution of a neutral metal carbonyl compound in an organicsolvent. In certain embodiments, the second catalyst feed streamcomprises a slurry of a neutral metal carbonyl compound in an organicsolvent. In certain embodiments, the second catalyst feed streamcomprises an ether. In certain embodiments, the second catalyst feedstream comprises 1,4-dioxane. In certain embodiments, the secondcatalyst feed stream comprises a hydrocarbon solvent. In certainembodiments, the second catalyst feed stream comprises tetrahydrofuran.In certain embodiments, the second catalyst feed stream comprisesdiglyme.

In certain embodiments where at least one of the first or secondcarbonylation catalyst feed streams comprises an organic solvent, andwhere the epoxide carbonylation reaction is a continuous carbonylationprocess, the method is characterized in that there are no additionalsolvent feeds to the continuous reactor. Or put another way, the methodis characterized in that all of the reaction solvent fed to thecontinuous epoxide carbonylation reaction is provided via the catalystfeed streams.

As mentioned above, one advantage of methods of the present invention isthe ability to provide epoxide carbonylation catalysts that areessentially free of halide and/or alkali metal salt impurities.Therefore, in certain embodiments, the present invention encompassesmethods for feeding the reaction zone of an epoxide carbonylationreaction with carbonylation catalyst characterized in that the epoxidecarbonylation reaction zone remains essentially free of halide and/oralkali metal salt impurities introduced with the epoxide carbonylationcatalyst. In certain embodiments, such methods are characterized in thatthe epoxide carbonylation reaction zone is essentially free of halide.In certain embodiments, the methods are characterized in that theepoxide carbonylation reaction zone has a halide content less than about200 ppm. In certain embodiments, the methods are characterized in thatthe epoxide carbonylation reaction zone has a halide content less thanabout 150 ppm, less than about 100 ppm, less than about 50 ppm, lessthan about 40 ppm, less than about 30 ppm, less than about 20 ppm, lessthan about 10 ppm, less than about 5 ppm, less than about 2 ppm, or lessthan about 1 ppm. In certain embodiments, the methods are characterizedin that the epoxide carbonylation reaction zone is essentially free ofalkali metal salts. In certain embodiments, the methods arecharacterized in that the epoxide carbonylation reaction zone has analkali metal salt content less than about 200 ppm. In certainembodiments, the methods are characterized in that the epoxidecarbonylation reaction zone has an alkali metal salt content less thanabout 150 ppm, less than about 100 ppm, less than about 50 ppm, lessthan about 40 ppm, less than about 30 ppm, less than about 20 ppm, lessthan about 10 ppm, less than about 5 ppm, less than about 2 ppm, or lessthan about 1 ppm.

In certain embodiments of methods for providing carbonylation catalyststo an epoxide carbonylation reaction, a neutral metal carbonyl compoundprovided in the second catalyst feed stream has the general formulaQ′_(d)M_(e)(CO)_(w′), where each of Q′, M, d, e, and w′ is as definedabove and in the classes and subclasses herein. In certain embodiments,the neutral metal carbonyl provided in the second catalyst feed streamhas the general formula Q′M (CO)_(w′). In certain embodiments, a neutralmetal carbonyl provided in the second catalyst feed stream has thegeneral formula M(CO)_(w′). In certain embodiments, a neutral metalcarbonyl provided in the second catalyst feed stream has the generalformula Q′M₂(CO)_(w′). In certain embodiments, a neutral metal carbonylprovided in the second catalyst feed stream has the general formulaM₂(CO)_(w′). Suitable neutral metal carbonyl compounds include, but arenot limited to: Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆, Mo(CO)₆, W(CO)₆, Mn₂(CO)₁₀,Tc₂(CO)₁₀, Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅, Os(CO)₅, Ru₃(CO)₁₂, Os₃(CO)₁₂,Fe₃(CO)₁₂, Fe₂(CO)₉, Co₄(CO)₁₂, Rh₄(CO)₁₂, Rh₆(CO)₁₆, Ir₄(CO)₁₂,Co₂(CO)₈, and Ni(CO)₄.

In certain embodiments, a neutral metal carbonyl compound provided inthe second catalyst feed stream comprises a cobalt carbonyl compound. Incertain embodiments, a neutral metal carbonyl compound provided in thesecond catalyst feed stream is Co₂(CO)₈. In certain embodiments, aneutral metal carbonyl compound provided in the second catalyst feedstream is Co₄(CO)₁₂. In certain embodiments, a neutral metal carbonylcompound provided in the second catalyst feed stream is a mixture of twoor more cobalt carbonyl species.

In certain embodiments, the rate of addition of the first feed streamand the rate of addition of the second feed stream are controlled toprovide a particular molar ratio of compound I or I′ to the neutralmetal carbonyl compound. In certain embodiments, the ratio of the molarquantity of compound I or I′ fed to the carbonylation reactor per unittime to the molar quantity of metal carbonyl compound fed to thecarbonylation reactor per unit time is in the range of from about 0.1:1to about 10:1. In certain embodiments, the molar ratio of compound I orI′ to the neutral metal carbonyl compound fed to the carbonylationreactor per unit time is in the range of from 0.1:1 to 2:1; or from0.5:1 to 1.5:1; or from 0.7:1 to 1.5:1; or from 0.8:1 to 1.2:1; or from0.9:1 to 1.1:1. In certain embodiments, the molar ratio of compound I orI′ to the neutral metal carbonyl compound fed to the carbonylationreactor per unit time is in the range of from 1:1 to 5:1; or from 1:1 to4:1; or from 1:1 to 3:1; or from 1:1 to 2:1; or from 1.2:1 to 2.5:1; orfrom 1.4:1 to 2:1; or from 1.2:1 to 2:1; or from 1.5:1 to 2:1.

In certain embodiments, the molar ratio of compound I or I′ to theneutral metal carbonyl compound fed to the carbonylation reactor perunit time is controlled in the methods herein such that the molar ratioof aluminum atoms from the provided compound I or I′ to metal atoms fromthe provided neutral metal carbonyl compound is in the range of about0.5:1 to about 2:1. For example, if a neutral metal carbonyl compound isdicobalt octacarbonyl, and compound I or I′ is an aluminum porphyrincomplex, a feed rate providing 2:1 molar ratio of compound I or I′ to aneutral metal carbonyl per unit time would provide a 1:1 molar ratio ofcobalt to aluminum atoms in the reaction zone. In certain embodiments,the ratio of the of aluminum atoms provided by addition of the firstcatalyst feed stream to metal atoms in a neutral metal carbonyl compoundprovided by addition the second catalyst feed stream is in the range offrom 0.5:1 to about 1.5:1, or from 0.7:1 to about 1.3:1, or from 0.8:1to about 1.2:1, or from 0.9:1 to about 1.2:1, or from 0.9:1 to about1.1:1, or from 0.95:1 to about 1.05:1. In certain embodiments, the ratioof the of aluminum atoms provided by addition of the first catalyst feedstream to metal atoms in a neutral metal carbonyl compound provided byaddition the second catalyst feed stream is in the range of from about1:1 to about 1:2, or from about 1:1 to about 1:1.8, or from about 1:1 toabout 1:1.5, or from about 1:1 to about 1:1.4, or from about 1:1 toabout 1:1.3, or from about 1:1 to about 1:1.2 or from about 1:1 to about1:1.1.

In certain embodiments, the rate of addition of the first catalyst feedstream and the rate of addition of the second catalyst feed stream areset such that within the epoxide carbonylation reaction zone, the molarratio of metal atoms from a provided neutral metal carbonyl compound toaluminum atoms from the provided compound I or I′ is maintained at aratio of about 1:1.

In certain embodiments the present invention encompasses a method forproviding carbonylation catalysts to an epoxide carbonylation reaction,the method comprising the step of feeding a carbonylation reactorcomprising a reaction zone where one or more epoxides is in contact withcarbon monoxide with carbonylation catalyst by providing two separatecatalyst feed streams: a first catalyst feed stream containing acompound of formula I or I′ (as defined above and in the classes andsubclasses herein) and a second catalyst feed stream containing aneutral cobalt carbonyl compound.

In certain embodiments, the first catalyst feed stream and the secondcatalyst feed stream are added to the epoxide carbonylation reactor attwo separate entry points. In other embodiments, the first catalyst feedstream and the second catalyst feed stream are combined at the entry tothe epoxide carbonylation reactor. In certain embodiments, the firstcatalyst feed stream and the second catalyst feed stream are combinedprior to their entry to the epoxide carbonylation reactor, for exampleby flowing through a mixing tee or a static mixer prior to entry to theepoxide carbonylation reactor. In certain embodiments where the firstcatalyst feed stream and the second catalyst feed stream are combinedprior to their entry to the epoxide carbonylation reactor they arecombined in the presence of carbon monoxide. In certain embodiments,provision is made for a controlled contact time of the first and secondcatalyst feed streams prior to their introduction to the epoxidecarbonylation reactor. In certain embodiments, the controlled contacttime is in the range of 0.5 seconds to 60 minutes. In certainembodiments, the controlled contact time is in the range from 0.5seconds to 30 seconds, from 0.5 seconds to 10 seconds, from 10 secondsto 30 seconds, or from 20 seconds to 30 seconds. In certain embodiments,the controlled contact time is in the range from 30 seconds to 5minutes, from 30 seconds to 1 minute, from 1 minute to 2 minutes, orfrom 2 minutes to 5 minutes. In certain embodiments, the controlledcontact time is in the range from 5 minutes to 10 minutes, from 10minutes to 20 minutes, from 15 minutes to 30 minutes, or from 30 minutesto 60 minutes. In certain embodiments, the contact time is controlled bya control loop based on an analytical measurement of the combinedcatalyst feed streams. Suitable analytical methods include, but are notlimited to: infrared (IR) spectroscopy, ultraviolet-visible absorption(UV-vis) spectroscopy, mass spectroscopy, gas chromatography (GC),liquid chromatography, and combinations of two or more of these. Incertain embodiments, the analytical method measures one or more of:disappearance of the neutral metal carbonyl compound, disappearance ofthe aluminum precursor (e.g. I or I′), formation of the desiredcatalyst, formation of a ketone (e.g. R^(q)COR^(q)), or combinations oftwo or more of these.

For any of the methods above, the epoxide present in the epoxidecarbonylation reactor may be ethylene oxide, or any substituted epoxide.In certain embodiments, the epoxide present in the epoxide carbonylationreactor has a formula:

-   -   wherein:    -   R^(a′) is hydrogen or an optionally substituted group selected        from the group consisting of C₁₋₃₀ aliphatic; C₁₋₃₀        heteroaliphatic having 1-4 heteroatoms independently selected        from the group consisting of nitrogen, oxygen, and sulfur; 6- to        10-membered aryl; 5- to 10-membered heteroaryl having 1-4        heteroatoms independently selected from nitrogen, oxygen, and        sulfur; and 4- to 7-membered heterocyclic having 1-3 heteroatoms        independently selected from the group consisting of nitrogen,        oxygen, and sulfur;    -   each of R^(b′), R^(c′), and R^(d′) is independently hydrogen or        an optionally substituted group selected from the group        consisting of C₁₋₁₂ aliphatic; C₁₋₁₂ heteroaliphatic having 1-4        heteroatoms independently selected from the group consisting of        nitrogen, oxygen, and sulfur; 6- to 10-membered aryl; 5- to        10-membered heteroaryl having 1-4 heteroatoms independently        selected from nitrogen, oxygen, and sulfur; and 4- to 7-membered        heterocyclic having 1-3 heteroatoms independently selected from        the group consisting of nitrogen, oxygen, and sulfur;    -   wherein any of (R^(b′) and R^(c′)), (R^(c′) and R^(d′)), and        (R^(a′) and R^(b′)) can be taken together with their intervening        atoms to form one or more rings selected from the group        consisting of: optionally substituted C₃-C₁₄ carbocycle,        optionally substituted C₃-C₁₄ heterocycle, optionally        substituted C₆-C₁₀ aryl, and optionally substituted C₅-C₁₀        heteroaryl.

In certain embodiments, an epoxide present in the epoxide carbonylationreactor is selected from the group consisting of: ethylene oxide,propylene oxide, 1,2 butylene oxide, 2,3 butylene oxide, epoxides ofhigher alpha olefins, epichlorohydrin, glycidyl ethers, cyclohexeneoxide, cyclopentene oxide, 3-vinyl cyclohexene oxide, 3-ethylcyclohexene oxide, and diepoxides.

In certain embodiments, an epoxide present in the epoxide carbonylationreactor may comprise a mixture of any two or more of the above epoxides.(Thus, when an epoxide “comprises”, e.g., ethylene oxide, it isunderstood that the provided epoxide can be ethylene oxide, or ethyleneoxide in combination with one or more epoxides.)

In certain embodiments, the provided epoxide consists of ethylene oxide.

In certain embodiments, a provided epoxide consists of propylene oxide.In certain embodiments, the provided propylene oxide is enantioenriched.

In certain embodiments, epoxide carbonylation reactions in the methodsabove are characterized in that a product of the epoxide carbonylationis selected from the group consisting of: beta lactone, cyclicanhydride, 3-hydroxy carboxylic acid or an ester thereof, or a polyesterformed by alternating copolymerization of the epoxide and carbonmonoxide.

In certain embodiments, the epoxide carbonylation reactions in themethods above are characterized in that a product of the epoxidecarbonylation is a beta propiolactone derivative:

where each R^(a′), R^(b′), R^(c′), and R^(d′) is as defined above and inthe classes and subclasses herein.

In certain embodiments, the epoxide carbonylation reactions in themethods above are characterized in that a product of the epoxidecarbonylation is a succinic anhydride derivative:

where each R^(a′), R^(b′), R^(c′), and R^(d′) is as defined above and inthe classes and subclasses herein.

In certain embodiments, the epoxide carbonylation reactions in themethods above are characterized in that a product of the epoxidecarbonylation is a 3-hydroxy propionic acid derivative:

where each R^(a′), R^(b′), R^(c′), and R^(d′) is as defined above and inthe classes and subclasses herein.

In certain embodiments, the epoxide carbonylation reactions in themethods above are characterized in that a product of the epoxidecarbonylation is an ester of a 3-hydroxy propionic acid derivative:

where each R^(a′), R^(b′), R^(c′), and R^(d′) is as defined above and inthe classes and subclasses herein, and R^(v) is selected from the groupconsisting of optionally substituted C₁₋₁₂ aliphatic and optionallysubstituted aryl, or R^(v) is selected from the group consisting ofmethyl, ethyl, n-propyl, isopropyl, n-butyl, i-butyl, s-butyl, t-butyl,and 2-ethylhexyl, or R^(v) is selected from the group consisting ofmethyl, ethyl, n-butyl, and 2-ethylhexyl.

In certain embodiments, the epoxide carbonylation reactions in themethods above are characterized in that a product of the epoxidecarbonylation is a poly-3-hydroxy propionic acid derivative:

where each R^(a′), R^(b′), R^(c′), and R^(d′) is as defined above and inthe classes and subclasses herein.

In certain embodiments, the epoxide is ethylene oxide and the product ofthe epoxide carbonylation reaction comprises beta propiolactone. Incertain embodiments, the epoxide is ethylene oxide and the product ofthe epoxide carbonylation reaction comprises succinic anhydride. Incertain embodiments, the epoxide is ethylene oxide and the product ofthe epoxide carbonylation reaction comprises 3-hydroxy propionic acid.In certain embodiments, the epoxide is ethylene oxide and the product ofthe epoxide carbonylation reaction comprises the methyl-, ethyl-,propyl-, butyl-, or 2-ethylhexyl ester of 3-hydroxy propionic acid. Incertain embodiments, the epoxide is ethylene oxide and the product ofthe epoxide carbonylation reaction comprises polypropiolactone.

In certain embodiments, the epoxide is propylene oxide and the productof the epoxide carbonylation reaction comprises beta butyrolactone. Incertain embodiments, the epoxide is propylene oxide and the product ofthe epoxide carbonylation reaction comprises methyl succinic anhydride.In certain embodiments, the epoxide is propylene oxide and the productof the epoxide carbonylation reaction comprises 3-hydroxy butyric acid.In certain embodiments, the epoxide is propylene oxide and the productof the epoxide carbonylation reaction comprises poly-3-hydroxy butyrate(PHB).

In certain embodiments, the methods above are adapted to feed acarbonylation reactor where the substrate is other than an epoxide. Suchnon-epoxide substrates include beta lactones, aziridines, and oxetanes.In certain embodiments, the methods above are adapted to feed acontinuous carbonylation reactor where beta propiolactone iscarbonylated to provide succinic anhydride.

IV. Detailed Description of the Aluminum Complex

In the methods and compositions described above, various aluminumcomplexes are described and depicted as an aluminum atom coordinated tofour Q groups, for example in formulae I and I′ and

etc. this section describes these compounds in greater detail.

In certain embodiments, the four Q groups associated with the aluminumatom in the compounds herein are part of a single tetradentate ligand.In certain embodiments, the four Q groups are part of two or moreseparate ligands, for example, a combination of two bidendate ligands(which may be the same or different), or a combination of a tridentateligand and a monodentate ligand. In certain embodiments, all four Qgroups comprise nitrogen atoms. In certain embodiments, the Q groupscomprise nitrogen and oxygen atoms (for example two N and two O, three Nand one O, or three O and one N). In certain embodiments, all four Qgroups comprise oxygen atoms.

In embodiments where the four Q groups associated with the aluminum atomare part of a single tetradentate ligand, the tetradentate ligand isselected from the group consisting of: porphyrin derivatives 1, salenderivatives 2, dibenzotetramethyltetraaza[14]annulene (tmtaa)derivatives 3, phthalocyaninate derivatives 4, derivatives of the Trostligand 5, and tetraphenylporphyrin derivatives 6, as depicted below. Incertain embodiments, the multidentate ligand is a salen derivative. Inother embodiments, the multidentate ligand is a tetraphenylporphyrinderivative.

here

-   -   R^(c) is independently at each occurrence hydrogen, halogen,        —OR, —NR^(y) ₂, —SR^(y), —CN, —NO₂, —SO₂R^(y), —SOR^(y),        —SO₂NR^(y) ₂; —CNO, —NRSO₂R^(y), —NCO, —N₃, —SiR₃; or an        optionally substituted group selected from the group consisting        of C₁₋₂₀ aliphatic; C₁₋₂₀ heteroaliphatic having 1-4 heteroatoms        independently selected from the group consisting of nitrogen,        oxygen, and sulfur; 6- to 10-membered aryl; 5- to 10-membered        heteroaryl having 1-4 heteroatoms independently selected from        nitrogen, oxygen, or sulfur; and 4- to 7-membered heterocyclic        having 1-2 heteroatoms independently selected from the group        consisting of nitrogen, oxygen, and sulfur;    -   R^(d) is independently at each occurrence hydrogen, halogen,        —OR⁴, —NR^(y) ₂, —SR, —CN, —NO₂, —SO₂R^(y), —SOR^(y), —SO₂NR^(y)        ₂; —CNO, —NRSO₂R^(y), —NCO, —N₃, —SiR₃; or an optionally        substituted group selected from the group consisting of C₁₋₂₀        aliphatic; C₁₋₂₀ heteroaliphatic having 1-4 heteroatoms        independently selected from the group consisting of nitrogen,        oxygen, and sulfur; 6- to 10-membered aryl; 5- to 10-membered        heteroaryl having 1-4 heteroatoms independently selected from        nitrogen, oxygen, or sulfur; and 4- to 7-membered heterocyclic        having 1-2 heteroatoms independently selected from the group        consisting of nitrogen, oxygen, and sulfur, where        -   two or more R^(d) groups may be taken together to form one            or more optionally substituted rings,        -   each R^(y) is independently hydrogen, or an optionally            substituted group selected the group consisting of: acyl;            carbamoyl, arylalkyl; 6- to 10-membered aryl; C₁₋₁₂            aliphatic; C₁₋₁₂ heteroaliphatic having 1-2 heteroatoms            independently selected from the group consisting of            nitrogen, oxygen, and sulfur; 5- to 10-membered heteroaryl            having 1-4 heteroatoms independently selected from the group            consisting of nitrogen, oxygen, and sulfur; 4- to 7-membered            heterocyclic having 1-2 heteroatoms independently selected            from the group consisting of nitrogen, oxygen, and sulfur;            an oxygen protecting group; and a nitrogen protecting group;            where two R^(y) on the same nitrogen atom may be taken with            the nitrogen atom to form an optionally substituted 4- to            7-membered heterocyclic ring having 0-2 additional            heteroatoms independently selected from the group consisting            of nitrogen, oxygen, and sulfur,        -   R⁴ is a hydroxyl protecting group or R^(y), and        -   R is independently at each occurrence optionally substituted            C₁₋₁₂ aliphatic or optionally substituted aryl;    -   R^(1a), R^(1a′), R^(2a), R^(2a′), R^(3a), and R^(3a′) are        independently hydrogen, halogen, —OR⁴, —NR^(y) ₂, —SR^(y), —CN,        —NO₂, —SO₂R^(y), —SOR, —SO₂NR^(y) ₂; —CNO, —NRSO₂R, —NCO, —N₃,        —SiR₃; or an optionally substituted group selected from the        group consisting of C₁₋₂₀ aliphatic; C₁₋₂₀ heteroaliphatic        having 1-4 heteroatoms independently selected from the group        consisting of nitrogen, oxygen, and sulfur; 6- to 10-membered        aryl; 5- to 10-membered heteroaryl having 1-4 heteroatoms        independently selected from nitrogen, oxygen, or sulfur; and 4-        to 7-membered heterocyclic having 1-2 heteroatoms independently        selected from the group consisting of nitrogen, oxygen, and        sulfur, where        -   any of (R^(2a′) and R^(3a′)), (R^(2a) and R^(3a)), (R^(1a)            and R^(2a)), and (R^(1a′) and R^(2a′)) may optionally be            taken together with the carbon atoms to which they are            attached to form one or more rings which may in turn be            substituted with one or more R^(d) groups; and    -   R^(4a) is selected from the group consisting of:

-   -    where,        -   two or more Re groups may be taken together with the carbon            atoms to which they are attached and any intervening atoms            to form one or more rings,        -   when two R^(c) groups are attached to the same carbon atom,            they may be taken together along with the carbon atom to            which they are attached to form a moiety selected from the            group consisting of: a 3- to 8-membered spirocyclic ring, a            carbonyl, an oxime, a hydrazone, an imine, and        -   Y is a divalent linker selected from the group consisting            of: —[C(R^(c))₂]_(q)—, —NR^(y)—, —N(R)C(O)—, —C(O)NR^(y)—,            —O—, —C(O)—, —OC(O)—, —C(O)O—, —S—, —SO—, —SO₂—, —C(═S)—,            —C(═NR^(y))—, —N═N—; a polyether; a C₃ to C₈ substituted or            unsubstituted carbocycle; and a C₁ to C₈ substituted or            unsubstituted heterocycle;    -   m is 0 or an integer from 1 to 6, inclusive;    -   m′ is 0 or an integer from 1 to 4, inclusive;    -   q is 0 or an integer from 1 to 4, inclusive; and    -   x is 0, 1, or 2.

In certain embodiments, the moiety

in the methods and compounds above comprises an aluminum-porphinatocomplex.

In certain embodiments, the aluminum-porphinato complex has a structure:

-   -   where each R^(d) is independently as defined above and in the        classes and subclasses herein.

In certain embodiments, the aluminum-porphinato complex has a structureselected from the group consisting of:

In certain embodiments, the aluminum-porphinato complex has thestructure:

-   -   where each R^(d) is independently as defined above and in the        classes and subclasses herein.

In certain embodiments, the aluminum-porphinato complex has thestructure:

In certain embodiments, the aluminum-porphinato complex has a structureselected from the group consisting of:

In certain embodiments, the moiety

in the compounds and methods above comprises an aluminum-phthalocyaninecomplex.

In certain embodiments, the moiety

in the compounds and methods described herein has a structure:

-   -   where R^(d) is independently at each occurrence as defined above        and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods above comprises an aluminum-salen complex.

In certain embodiments, the moiety

in the compounds and methods described herein has a structure:

-   -   where each of R^(1a), R^(1a′), R^(2a), R^(2a′), R^(3a), R^(3a′)        and R^(4a), is as defined above and in the classes and        subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure Ia:

-   -   where each R^(d) and R^(4a) is independently as defined above        and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(d) and R^(4a) is independently as defined above        and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where R^(4a) is as defined above and in the classes and        subclasses herein, and    -   R^(1′) and R^(3′) are, independently at each occurrence,        selected from the group consisting of: hydrogen, halogen,        optionally substituted C₁₋₂₀ aliphatic, optionally substituted        aryl, and OR^(y), where R^(y) is as defined above.

In certain embodiments, R^(1′) and R^(3′) are, independently at eachoccurrence, selected from the group consisting of: hydrogen, optionallysubstituted C₁₋₁₂ aliphatic and optionally substituted aryl. In certainembodiments, at least one occurrence of R^(1′) or R^(3′) is hydrogen. Incertain embodiments, at least one occurrence of R^(1′) or R^(3′) is C₁₋₆aliphatic. In certain embodiments, at least one occurrence of R^(1′) orR^(3′) is substituted C₁₋₆ aliphatic. In certain embodiments, at leastone occurrence of R¹ or R^(3′) is optionally substituted aryl.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(c) and R^(d) is independently as defined above and        in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(c), R^(1′), and R^(3′) is independently as defined        above and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(1′), and R^(3′) is independently as defined above        and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein is selected from the groupconsisting of:

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(1′) and R^(3′) is independently as defined above        and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein is selected from the groupconsisting of:

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(d) is independently as defined above in the        classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each R^(d), R^(1′), and R^(3′) is independently as defined        above and in the classes and subclasses herein.

In certain embodiments, the moiety

in the compounds and methods described herein is selected from the groupconsisting of:

In certain embodiments, the moiety

in the compounds and methods described herein comprises analuminum-tmtaa complex.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where R^(d) is independently at each occurrence as defined above        and in the classes and subclasses herein, and    -   R^(e) at each occurrence is independently hydrogen, halogen,        —OR, —NR₂, —SR, —CN, —NO₂, —SO₂R, —SOR, —SO₂NR₂; —CNO, —NRSO₂R,        —NCO, —N₃, —SiR₃; or an optionally substituted group selected        from the group consisting of C₁₋₂₀ aliphatic; C₁₋₂₀        heteroaliphatic having 1-4 heteroatoms independently selected        from the group consisting of nitrogen, oxygen, and sulfur; 6- to        10-membered aryl; 5- to 10-membered heteroaryl having 1-4        heteroatoms independently selected from nitrogen, oxygen, or        sulfur; and 4- to 7-membered heterocyclic having 1-2 heteroatoms        independently selected from the group consisting of nitrogen,        oxygen, and sulfur.

In certain embodiments, the moiety

in the compounds and methods described herein has the structure:

-   -   where each of R^(c) and R^(d) is as defined above and in the        classes and subclasses herein.

In certain embodiments, for any of the aluminum complexes above havingone or more R^(d) groups, each occurrence of R^(d) is independentlyselected from the group consisting of: hydrogen, halogen, optionallysubstituted C₁₋₆ aliphatic, or optionally substituted aryl. In certainembodiments, each R^(d) is hydrogen, optionally substituted C₁₋₆aliphatic, or optionally substituted aryl. In some embodiments, eachR^(d) is hydrogen. In certain embodiments, at least one R^(d) isoptionally substituted C₁₋₆ aliphatic. In certain embodiments, at leastone R^(d) is optionally substituted C₁₋₄ aliphatic. In some embodiments,at least one R^(d) is optionally substituted aryl. In some embodiments,R^(d) is substituted phenyl. In some embodiments, at least one R^(d) isunsubstituted phenyl. In some embodiments, at least one R^(d) is phenylsubstituted with one or more substituents selected from the groupconsisting of halogen, —NO₂, —CN, C₁₋₆ aliphatic optionally substitutedwith one or more halogens, and —OC₁₋₆ aliphatic.

In certain embodiments, for any of the aluminum complexes above havingone or more R^(c) groups, each occurrence of Re is independentlyselected from the group consisting of: hydrogen, halogen, optionallysubstituted C₁₋₆ aliphatic and optionally substituted aryl. In someembodiments, each R² is hydrogen, halogen, or optionally substitutedC₁₋₆ aliphatic. In some embodiments, each R² is hydrogen. In someembodiments, R² is optionally substituted C₁₋₆ aliphatic. In someembodiments, R² is ethyl. In some embodiments, R² is methyl.

The compounds of formula I in the methods herein have a carbonsubstituent bonded to the aluminum atom denoted R^(q). As describedabove, R^(q) is an optionally substituted aliphatic group or aryl group.In certain embodiments, R^(q) is a C₁₋₂₀ aliphatic group. In certainembodiments, R^(q) is a C₁₋₁₂ aliphatic group. In certain embodiments,R^(q) is a C₁₋₈ aliphatic group. In certain embodiments, R^(q) is a C₁₋₆aliphatic group. In certain embodiments, R^(q) is a C₁₋₄ aliphaticgroup.

In certain embodiments, R^(q) is selected from the group consisting ofmethyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and octyl. Incertain embodiments, R^(q) is ethyl. In certain embodiments, R^(q) ismethyl.

In certain embodiments, R^(q) may correspond to an alkyl group of anavailable trialkyl aluminum compound. Several trialkylaluminum reagentsare commercially available and processes for the preparationtrialkylaluminum reagents are well known in the art: for example, bymethods described in U.S. Pat. Nos. 3,006,942 and 3,960,912 (thecontents of each of which are incorporated herein by reference). In someembodiments, a trialkylaluminum reagent is trimethylaluminum. In someembodiments, a trialkylaluminum reagent is triethylaluminum. In someembodiments, a trialkylaluminum reagent is tripropylaluminum. In someembodiments, a trialkylaluminum reagent is triisobutylaluminum. In someembodiments, a trialkylaluminum reagent is trioctylaluminum.

In some embodiments, compounds of formula I may be conveniently obtainedby treatment of suitable protic ligands (e.g. compounds having one ormore Q-H groups) with a trialkyl aluminum reagent such as thosedescribed above. This typically results in the displacement of one ormore of the alkyl groups from the aluminum by Q-groups. For example, inthe case where compound I is an aluminum tetraphenyl porphyrin complex,it may be obtained according to the reaction shown in Scheme 1:

Similar means can be utilized to form other compounds of formula I bycombining trialkyl aluminums with suitable protic ligands such as thosedescribed above. The skilled artisan will recognize that the reactionconditions will need to be controlled and modified to account for thereactivity of certain ligands or ligand precursors and that strategiessuch as controlled addition rates, lowered temperatures, selection ofparticular solvents and additives may be necessary to obtain the desiredcompounds. Such methods and conditions will constitute routineexperimentation to those skilled in the art of organometallic synthesis.

V. Methods of Making Ketones

In another aspect, the present invention encompasses methods for thesynthesis of symmetrical ketones.

In certain embodiments, such methods comprise the step of contacting analuminum compound of formula I:

with a neutral metal carbonyl compound (as defined above and in theclasses and subclasses herein) to provide a product having a formula:

where each of Q and R^(q) are as defined above and in the classes andsubclasses herein.

In certain embodiments, compound I comprises an aluminum porphyrincomplex.

In certain embodiments, R^(q) is a C₁₋₂₀ aliphatic group. In certainembodiments, R^(q) is a C₁₋₁₂ aliphatic group. In certain embodiments,R^(q) is a C₁₋₈ aliphatic group. In certain embodiments, R^(q) is a C₁₋₆aliphatic group. In certain embodiments, R^(q) is a C₁₋₄ aliphaticgroup.

In certain embodiments, R^(q) is selected from the group consisting ofmethyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and octyl. Incertain embodiments, R^(q) is ethyl. In certain embodiments, R^(q) ismethyl.

In certain embodiments of the inventive methods for synthesizingketones, the neutral metal carbonyl compound provided has the generalformula Q′_(d)M_(e)(CO)_(w′), where each Q′, M, d, and e, is as definedabove and in the classes and subclasses herein and w′ is a number suchas to provide a stable neutral metal carbonyl complex. In certainembodiments, the neutral metal carbonyl has the general formulaQ′M(CO)_(w′). In certain embodiments, the neutral metal carbonyl has thegeneral formula M(CO)_(w′). In certain embodiments, the neutral metalcarbonyl has the general formula Q′M₂(CO)_(w′). In certain embodiments,the neutral metal carbonyl has the general formula M₂(CO)_(w′). Suitableneutral metal carbonyl compounds include, but are not limited to:Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆, Mo(CO)₆, W(CO)₆, Mn₂(CO)₁₀, Tc₂(CO)₁₀,Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅, Os(CO)₅, Ru₃(CO)₁₂, Os₃(CO)₁₂, Fe₃(CO)₁₂,Fe₂(CO)₉, Co₄(CO)₁₂, Rh₄(CO)₁₂, Rh₆(CO)₁₆, Ir₄(CO)₁₂, Co₂(CO)₈, andNi(CO)₄. The term “such as to provide a stable neutral metal carbonylfor Q′_(d)M_(e)(CO)_(w′) is used herein to mean thatQ′_(d)M_(e)(CO)_(w′) is a species characterizable by analytical means,e.g., NMR, IR, X-ray crystallography, Raman spectroscopy and/or electronspin resonance (EPR) and isolable in pure form or a species formed insitu. It is to be understood that metals which can form stable metalcarbonyl complexes have known coordinative capacities and propensitiesto form polynuclear complexes which, together with the number andcharacter of optional ligands Q that may be present will determine thenumber of sites available for CO to coordinate and therefore the valueof w′. Typically, such compounds conform to stoichiometries conformingto the “18-electron rule”. Such knowledge is within the grasp of onehaving ordinary skill in the arts pertaining to the synthesis andcharacterization of metal carbonyl compounds.

In certain embodiments of the inventive methods for synthesizingketones, a neutral metal carbonyl compound provided is a cobalt carbonylcompound. In certain embodiments of the inventive methods forsynthesizing ketones, a neutral metal carbonyl compound provided isdicobalt octacarbonyl.

In certain embodiments of the inventive methods for synthesizingketones, a compound of formula I and a neutral metal carbonyl compoundare contacted under CO pressure. In certain embodiments, the CO pressureis in the range from about 2 atmospheres to about 400 atmospheres. Incertain embodiments, compound I and the neutral metal carbonyl compoundare contacted under an atmosphere comprising CO at a pressure betweenabout 2 atmospheres and about 100 atmospheres, or between about 5atmosphere and about 50 atmospheres, or between about 10 atmospheres andabout 20 atmospheres, or between about 20 atmospheres and about 50atmospheres, or between about 50 atmospheres and about 100 atmospheres.

EXAMPLES General

All synthetic experiments were done under N₂. THF was purified bypassing through OxiClear™ column. Anhydrous hexanes was purchased fromAldrich and bubbled with N₂ for 2 h before use.

Example 1—Syntheses of [(TPP)Al(THF)₂][Co(CO)₄] with Aluminum Alkyls

In a 2 L flask, 60.0 g of (TPP)AlEt was dissolved in 1120 mL of THF. Tothe solution, 16.2 g of Co₂(CO)₈ containing 1-5 wt % hexanes was added.The reaction was stirred at room temperature for 16 h under 7 psig ofCO. After the reaction, the reaction mixture was filtered through afrit. The filtrate was then transferred to a 5 L flask. While stirred,2240 mL of anhydrous hexanes was added to the filtrate. The mixture wasallowed to stand for 24-72 h. The resulting purple precipitate wasfiltered by a frit, rinsed with fresh hexanes and dried under vacuum(79.2 g). From ICP-AES and ¹H-NMR in THF d-8, the product was confirmedto be [(TPP)Al(THF)₂][Co(CO)₄].

The same procedure as described above was used, except that 2.0 g of(TPP)AlEt, 0.9 g of Co₄(CO)₁₂, and 40 mL of THF were used for thereaction and the reaction was stirred for 4 days under 7 psig of CO. Thereaction produced 2.6 g of a purple solid, which was confirmed to be[(TPP)Al(THF)₂][Co(CO)₄] by ¹H NMR and ICP-AES.

Example 2—Synthesis of [(TPP)Al(THF)₂][Co(CO)₄] with Aluminum Propionate

In a 50 mL flask, 42.6 mg of (TPP)AlOC(O)CH₂CH₃, 21.7 mg of Co₂(CO)₈,and 10 mL of THF were added. The mixture was stirred overnight. Afterthe reaction, the reaction was stripped of volatiles. The remainingsolid was confirmed to contain [(TPP)Al(THF)₂][Co(CO)₄] by 1H NMR in THFd-8.

Example 3—Sodium Content of Aluminum Complexes

Using ICP-AES, the sodium content of the products of Examples 1 and 2was measured and found to be below the detectable limit. In contrast,the sodium content of the same complexes prepared by salt metathesiswere found to have sodium wt % in the range of 0.04 to 0.23 for 10different preparations.

Example 4—Synthesis of Ketones

In an NMR spectrum of the reaction product resulting from treatment of(TPP)AlEt with 0.5 eq. of Co₂(CO)₈, 0.24 molar equiv. of pentanone(relative to the catalyst) was observed in the ¹H NMR spectrum after thereaction. In addition, butane was detected in the volatiles from thefiltrate and hexanes wash of the crystallized catalyst.

Example 5—Additional Syntheses

Using the procedures described in Examples 1 and 2, the aluminumcomplexes [(OEP)Al(THF)₂][Co(CO)₄] and [(MeOTPP)Al(THF)₂][Co(CO)₄] canalso be made by starting with the appropriate aluminum ligand (i.e.,octaethylporphyrin or 5,10,15,20-tetrakis(4-methoxyphenyl)porphyrin).

Example 6—Continuous Carbonylation Processes

An exemplary embodiment for a continuous carbonylation process isdepicted in FIG. 1. Carbon monoxide, epoxide, a first catalyst stream(1), and a second catalyst stream (2) as described here are fed to acarbonylation reactor 100 (e.g., a CSTR). The product stream 101 is fedto catalyst separator 100 b for the removal (e.g., via nanofiltration)of carbonylation catalyst. The carbonylation product stream is withdrawnvia 102, while a recycling loop R1 feeds carbonylation catalyst back tothe carbonylation reactor 100.

FIG. 2 depicts a similar embodiment with an alternative approach ofpre-mixing the first catalyst stream and second catalyst stream in amixer 100 a prior to feeding into the carbonylation reactor 100.

OTHER EMBODIMENTS

It is to be understood that the embodiments of the invention hereindescribed are merely illustrative of the application of the principlesof the invention. Therefore, it will be appreciated that the scope ofthis invention is to be defined by the appended claims rather than bythe specific embodiments that have been presented by way of example.

1. A method for preparing an aluminum-based carbonylation catalyst offormula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound, wherein Q is independently ateach occurrence a nitrogen or oxygen atom which is part of a ligandcomplexed to the aluminum atom, where any two or more Q groups maycomprise part of a single ligand; R^(q) is selected from optionallysubstituted C₁₋₁₂ aliphatic and optionally substituted aryl; M is ametal atom; Q′ is any ligand and need not be present; d is an integerbetween 0 and 8 inclusive; e is an integer between 1 and 6 inclusive; wis a number such as to provide the stable anionic metal carbonylcomplex; and y is the charge of the metal carbonyl anion.
 2. A methodfor preparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound for formula I′:

with a neutral metal carbonyl compound, wherein: Q is independently ateach occurrence a nitrogen or oxygen atom which is part of a ligandcomplexed to the aluminum atom, where any two or more Q groups maycomprise part of a single ligand; M is a metal atom; Q′ is any ligandand need not be present; d is an integer between 0 and 8 inclusive; e isan integer between 1 and 6 inclusive; w is a number such as to providethe stable anionic metal carbonyl complex; y is the charge of the metalcarbonyl anion; and R^(q′) is selected from —H, optionally substitutedC₁₋₄₀ aliphatic and optionally substituted aryl.
 3. A method forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound of formula I:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

where Q is independently at each occurrence a nitrogen or oxygen atomwhich is part of a ligand complexed to the aluminum atom, where any twoor more Q groups may comprise part of a single ligand; R^(q) is selectedfrom optionally substituted C₁₋₁₂ aliphatic and optionally substitutedaryl; M is a metal atom; Q′ is any ligand and need not be present; d isan integer between 0 and 8 inclusive; w is a number such as to providethe stable anionic metal carbonyl complex; R^(a′) is hydrogen or anoptionally substituted group selected from the group consisting of C₁₋₃₀aliphatic; C₁₋₃₀ heteroaliphatic having 1-4 heteroatoms independentlyselected from the group consisting of nitrogen, oxygen, and sulfur; 6-to 10-membered aryl; 5- to 10-membered heteroaryl having 1-4 heteroatomsindependently selected from nitrogen, oxygen, and sulfur; and 4- to7-membered heterocyclic having 1-3 heteroatoms independently selectedfrom the group consisting of nitrogen, oxygen, and sulfur; and each ofR^(b′), R^(c′), and R^(d′) is independently hydrogen or an optionallysubstituted group selected from the group consisting of C₁₋₁₂ aliphatic;C₁₋₁₂ heteroaliphatic having 1-4 heteroatoms independently selected fromthe group consisting of nitrogen, oxygen, and sulfur; 6- to 10-memberedaryl; 5- to 10-membered heteroaryl having 1-4 heteroatoms independentlyselected from nitrogen, oxygen, and sulfur; and 4- to 7-memberedheterocyclic having 1-3 heteroatoms independently selected from thegroup consisting of nitrogen, oxygen, and sulfur, wherein any of (R^(b′)and R^(c′)), (R^(c′) and R^(d′)), and (R^(a′) and R^(b′)) can be takentogether with their intervening atoms to form one or more rings selectedfrom the group consisting of: optionally substituted C₃-C₁₄ carbocycle,optionally substituted C₃-C₁₄ heterocycle, optionally substituted C₆-C₁₀aryl, and optionally substituted C₅-C₁₀ heteroaryl.
 4. A method forpreparing an aluminum-based carbonylation catalyst of formula:

the method comprising a step of contacting a compound for formula I′:

with a neutral metal carbonyl compound in the presence of carbonmonoxide and an epoxide of formula:

wherein: Q is independently at each occurrence a nitrogen or oxygen atomwhich is part of a ligand complexed to the aluminum atom, where any twoor more Q groups may comprise part of a single ligand; R^(q′) isselected from —H, optionally substituted C₁₋₄₀ aliphatic and optionallysubstituted aryl; M is a metal atom; Q′ is any ligand and need not bepresent; d is an integer between 0 and 8 inclusive; w is a number suchas to provide the stable anionic metal carbonyl complex; R^(a′) ishydrogen or an optionally substituted group selected from the groupconsisting of C₁₋₃₀ aliphatic; C₁₋₃₀ heteroaliphatic having 1-4heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; 6- to 10-membered aryl; 5- to 10-memberedheteroaryl having 1-4 heteroatoms independently selected from nitrogen,oxygen, and sulfur; and 4- to 7-membered heterocyclic having 1-3heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; and each of R^(b′), R^(c′), and R^(d′) isindependently hydrogen or an optionally substituted group selected fromthe group consisting of C₁₋₁₂ aliphatic; C₁₋₁₂ heteroaliphatic having1-4 heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; 6- to 10-membered aryl; 5- to 10-memberedheteroaryl having 1-4 heteroatoms independently selected from nitrogen,oxygen, and sulfur; and 4- to 7-membered heterocyclic having 1-3heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur, wherein any of (R^(b′) and R^(c′)),(R^(c′) and R^(d′)), and (R^(a′) and R^(b′)) can be taken together withtheir intervening atoms to form one or more rings selected from thegroup consisting of: optionally substituted C₃-C₁₄ carbocycle,optionally substituted C₃-C₁₄ heterocycle, optionally substituted C₆-C₁₀aryl, and optionally substituted C₅-C₁₀ heteroaryl.
 5. A method forproviding carbonylation catalysts to an epoxide carbonylation reaction,the epoxide carbonylation reaction comprising a reaction zone where anepoxide is contacted with carbon monoxide, the method comprising thestep of feeding the reaction zone with a first catalyst feed streamcontaining an aluminum complex of formula I and a second catalyst feedstream containing a neutral metal carbonyl compound, wherein thealuminum complex of formula I has a formula:

where Q is independently at each occurrence a nitrogen or oxygen atomwhich is part of a ligand complexed to the aluminum atom, where any twoor more Q groups may comprise part of a single ligand; and R^(q) isselected from optionally substituted C₁₋₁₂ aliphatic and optionallysubstituted aryl.
 6. A method of synthesizing a symmetrical ketonecomprising the step of contacting an aluminum compound of formula I:

with a neutral metal carbonyl compound to provide a product having aformula:

where Q is independently at each occurrence a nitrogen or oxygen atomwhich is part of a ligand complexed to the aluminum atom, where any twoor more Q groups may comprise part of a single ligand; and R^(q) isselected from optionally substituted C₁₋₁₂ aliphatic and optionallysubstituted aryl.
 7. The method of claim 1, wherein the moiety

comprises an aluminum-porphinato complex.
 8. The method of claim 7,wherein the aluminum-porphinato complex has a structure:

where R^(d) is independently at each occurrence hydrogen, halogen, —OR⁴,—NR^(y) ₂, —SR, —CN, —NO₂, —SO₂R, —SOR^(y), —SO₂NR^(y) ₂; —CNO, —NRSO₂R,—NCO, —N₃, —SiR₃; or an optionally substituted group selected from thegroup consisting of C₁₋₂₀ aliphatic; C₁₋₂₀ heteroaliphatic having 1-4heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; 6- to 10-membered aryl; 5- to 10-memberedheteroaryl having 1-4 heteroatoms independently selected from nitrogen,oxygen, or sulfur; and 4- to 7-membered heterocyclic having 1-2heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur, where two or more R^(d) groups may betaken together to form one or more optionally substituted rings, eachR^(y) is independently hydrogen, or an optionally substituted groupselected the group consisting of: acyl; carbamoyl, arylalkyl; 6- to10-membered aryl; C₁₋₁₂ aliphatic; C₁₋₁₂ heteroaliphatic having 1-2heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; 5- to 10-membered heteroaryl having 1-4heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; 4- to 7-membered heterocyclic having 1-2heteroatoms independently selected from the group consisting ofnitrogen, oxygen, and sulfur; an oxygen protecting group; and a nitrogenprotecting group; where two R^(y) on the same nitrogen atom may be takenwith the nitrogen atom to form an optionally substituted 4- to7-membered heterocyclic ring having 0-2 additional heteroatomsindependently selected from the group consisting of nitrogen, oxygen,and sulfur, R⁴ is a hydroxyl protecting group or R^(y), and R isindependently at each occurrence optionally substituted C₁₋₁₂ aliphaticor optionally substituted aryl.
 9. The method of claim 8, wherein thealuminum-porphinato complex has a structure selected from the groupconsisting of:


10. The method of claim 7, wherein the aluminum-porphinato complex hasthe structure:


11. The method of claim 10, wherein the aluminum-porphinato complex hasthe structure:


12. The method of claim 10, wherein the aluminum-porphinato complex hasa structure selected from the group consisting of:


13. The method of claim 1, wherein the neutral metal carbonyl compoundis selected from the group consisting of: Ti(CO)₇, V₂(CO)₁₂, Cr(CO)₆,Mo(CO)₆, W(CO)₆, Mn₂(CO)₁₀, Tc₂(CO)₁₀, Re₂(CO)₁₀, Fe(CO)₅, Ru(CO)₅,Os(CO)₅, Ru₃(CO)₁₂, Os₃(CO)₁₂, Fe₃(CO)₁₂, Fe₂(CO)₉, Co₄(CO)₁₂,Rh₄(CO)₁₂, Rh₆(CO)₁₆, Ir₄(CO)₁₂, Co₂(CO)₈, and Ni(CO)₄.
 14. The methodof claim 1, wherein the neutral carbonyl compound comprises a cobaltcarbonyl compound.
 15. The method of claim 14, wherein the cobaltcarbonyl compound comprises dicobalt octacarbonyl.
 16. The method ofclaim 1, wherein the composition of catalysts thus formed have halide oralkali metal salts in an amount less than about 200 ppm, less than about150 ppm, less than about 100 ppm, less than about 50 ppm, less thanabout 40 ppm, less than about 30 ppm, less than about 20 ppm, less thanabout 10 ppm, less than about 5 ppm, less than about 2 ppm, or less thanabout 1 ppm.